SERMAZ Powers Innovation with a Cobotic Palletizing Solution for Lactalis

SERMAZ

Sermaz is developing a cobotic palletizing solution within the Lactalis group.

In short

Founded in 1988, SERMAZ is a company specializing in the design and manufacturing of special machines. Located in Aussillon (Tarn), the company has in-house expertise in the fields of design office, automation, mechanics, and fine sheet metal work. SERMAZ currently has around fifteen employees and is expanding across a variety of industrial sectors: aeronautics, food processing, automotive, medical, sports facilities, water treatment, leather and textile industries, etc.

Enhancing ergonomics and safety in dairy product palletizing

Lactalis launched an automation initiative to address serious ergonomic and safety concerns at its milk pack palletizing and packaging station. The manual process was physically demanding and hazardous, exposing operators to repetitive strain and musculoskeletal disorders (MSDs).

The task involved palletizing dairy products—such as bottles and bricks—under challenging conditions. Operators had to frequently move around the pallet, apply adhesive tape with precision, and perform strenuous overhead movements. Most critically, they were required to climb onto roller conveyors to secure tape at the top of the pallet, repeating this motion up to 60 times per hour. These repetitive actions led to wrist pain, reduced accuracy, and increased product rejection due to carton damage.

To mitigate these risks, Lactalis integrated the Universal Robots UR10, a collaborative robot designed to reduce physical strain and improve consistency. The UR10 significantly lowered the risk of MSDs while enhancing precision and operational efficiency.

Recognizing the complexity of the task, Lactalis partnered with SERMAZ, a regional expert in collaborative robotics and a trusted integrator of Universal Robots solutions. With deep expertise in industrial automation, SERMAZ delivered a tailored cobotic solution that addressed the ergonomic challenges, improved safety, and optimized the palletizing process.

SERMAZ

Industry Food and Beverage

Country France

Number of employees 10 - 19

Cobot used UR10

Main value drivers:

Simplicity and intuitiveness of programming
Safe operation alongside the operator who keeps control
Increased productivity
Cobot adaptation and compatibility with the reel and cutting system
Fast ROI and minimal maintenance

Tasks solved by collaborative robots:

Palletization on several formats
Repetition and precision of the gesture
Better control of the quantity of material deposited
Save time when removing adhesive tape
Optimization of workstation organization and elimination of MSDs

Automation challenges solved:

Reducing the risk of damage to my products
Elimination of line driver MSDs
Easy integration on the palletizing line

How they did it

A compact, safe, and efficient cobotic system

The solution developed by SERMAZ, based on a UR10 cobot, had to be able to keep up with the increased volume required by the site, while being compact and secure. SERMAZ supported the Lactalis group throughout all stages of the process. Initially, the line operator responsible for palletizing held the dispenser in one hand and had to rotate around the pallet, taking great care not to cause any deformations on the corners of the goods, taking care to use the right amount of adhesive tape, regularly and respecting a precise pattern.

An automated and optimized workstation

The new automated workstation consists of a roller conveyor to transport half-pallets from point A to point B along the production line, and a gantry to which the UR10 cobot has been attached. Edges will recenter the pallets so that they are in the correct position. The operator starts the cycle on the human-machine interface. He selects the appropriate operation based on the type of pallets and products. The cobot then follows a precise path based on the desired series.

A product cycle in hidden time

As the pallet approaches, the cobot makes contact with it and completes its trajectory. It rotates around the half-pallets and precisely applies the adhesive tape using a dispenser. At the end of the cycle, the cobot cuts the tape and repositions itself at the starting point to release the pallet. Meanwhile, the line operator is busy with other tasks with higher added value.

Successful human-robot cooperation

The cobot handles the tying operation alone, with minimal human intervention. This is limited to changing the adhesive tape. A warning light alerts the line operator. When the operator presses the button, the cobot, equipped with a dispenser and a cutting system, will apply the adhesive along the pallet according to a requested pattern, a precise diagram that can be pre-programmed using the remote teach. The solution is controlled solely through this screen. The line operator generally masters this application in just half a day.

This application aims above all to reduce the strain on the line driver while preserving the quality of the packaged product.

Thierry Delsol, Director of Sermaz

Improved productivity, safety, and operator empowerment

Despite the complexity of STIVAL’s automation needs, TD Conception developed and delivered a custom chamfering solution in just two days. To support rapid decision-making, they provided 3D modeling of the cobotic cell, leading to immediate approval and full integration within three months. Leveraging in-house 3D printing, TD Conception accelerated tool design and avoided delays from external suppliers.

The solution exceeded expectations:

Zero post-installation intervention required
24/5 autonomous operation, ensuring high economic viability
80% time savings for the operator, now focused on quality control
Reduced physical strain and MSD risks, improving workplace ergonomics
Flexible redeployment planned for folding machine operations
Fast ROI and new growth opportunities for STIVAL

TD Conception’s approach not only met STIVAL’s productivity goals but also laid the foundation for scalable automation across its operations.

The automated workstation consists of a roller converyor that transports the pallets under the gantry on which the cobot is mounted. Once they arrive at the station, cylinders stop the pallets. Edges recenter the pallets so that they are in the correct position. Beforehand, the line operator selects the appropriate operation on the human-machine interface based on the pallet type. The cobot then follows a precise path based on the desired series.

As the pallet appraches, the cobot, equipped with a dispenser, comes into contact with it and navigates its path. Once the adhesive has been applied and the pallet has been palletized, a system cuts off the excess adhesive tape and the cobot withdraws. The pallet completes its journey.

The boot handles the palletizing operation alone, with a minimal human intervention. This is limited to changing the adhesive tape. A warning light alerts the line operator.

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