Revolutionizing Chimney Cap Production: MG Maintenance’s Cobotic Innovation Boosts Efficiency at Poujoulat

MG Maintenance

MG Maintenance integrates a cardboard cap forming solution at Poujoulat

In short

MG Maintenance (MGM), a certified Universal Robots integrator based in the Nouvelle-Aquitaine region, has developed a solution for forming cardboard caps for Poujoulat , the European leader in chimney systems (manufacturer of stainless steel chimney flues and roof outlets). Integrated into its production site in Saint-Symphorien in Nouvelle-Aquitaine, the cobotic cell operates almost autonomously. The benefits observed include reduced downtime and improved working conditions for operators in this position.

Poujoulat Tackles Repetitive Manual Tasks

Poujoulat was looking for an automated solution to free its operators from folding cardboard headgear. This was a tedious and repetitive task that they had to perform upstream of the core operation of their business: blowing rock wool into pipes serving as chimney flues. Indeed, with several hundred headgear to be produced daily, musculoskeletal disorders (MSDs) such as tendonitis in the wrists or elbows could sometimes appear among employees. In addition, due to its time-consuming nature, the manual operation caused downtime and reduced production rates. Finally, it did not offer added value for the operators.

The automation project specifically involved forming two models of caps, one larger and more complex than the other. Poujoulat already had a UR10 cobot for a press loading operation, and was keen to use it for a new application. Made possible by the great flexibility of Universal Robots cobots, this reassignment was orchestrated by MG Maintenance to automate this task, allowing its operators to fully concentrate on filling the pipes.

MG Maintenance

Industry Industrial automation and maintenance sector

Country France

Number of employees 24

Cobot used UR10

Main value drivers:

Simplicity and intuitiveness of the solution

Almost autonomous operation

Increased productivity

Tasks solved by collaborative robots:

Forming cardboard caps

Repetition and precision of the gesture

Automation challenges solved:

Adaptation of the cobot according to the series

Reduction of MSDs among operators

Integration in record time into the workshop

Time saving for the operator

How they did it

MGM Designs a Custom Cobotic Cell for Precision Cap Forming

MG Maintenance developed a fully integrated cobotic cell featuring a UR10 robot mounted on a metal table, equipped with a suction cup gripper, pallet, and a tailor-made forming tool and chute—delivering high-precision automation for Poujoulat’s cardboard cap production.

Streamlined Workflow and Enhanced Operator Efficiency

The cobot handles two cap models with adaptive forming techniques, including pre-bending for complex shapes. With sensor-controlled output and minimal operator intervention, the solution reduces downtime, improves ergonomics, and allows workers to focus on core production tasks.

Automation That Delivers on Efficiency, Safety, and Workforce Appeal

The cobotic solution developed by MG Maintenance successfully addressed Poujoulat’s initial challenge—eliminating a repetitive, low-value task and freeing operators to focus on duct insulation, the company’s core value-added operation. Operating in hidden time, the UR10 cobot significantly reduces downtime and streamlines workflow.

By fully automating the cap-forming process, the cobot minimizes physical strain and lowers the risk of musculoskeletal disorders (MSDs), such as wrist and elbow tendonitis, among employees. This not only improves working conditions but also contributes to long-term workforce sustainability.

Beyond operational gains, the automation initiative positions Poujoulat as a forward-thinking employer. In an industry facing labor shortages, investing in collaborative robotics enhances the company’s image as a modern, employee-conscious workplace—making it more attractive to current and future talent.

Manually folding cardboard covers was both a time-consuming and tedious operation for Poujoulat’s operators. Now, with the cobotic solution we developed, they only have to retrieve the boxes from the chute; they can fully focus on higher value-added operations.

Nicolas Bertand, Solutions Manager at MG Maintenance