Palletizing of pouch bag packages in open trays by Bauer

Cobot concept convinces Privatmolkerei Bauer

Although the palletizing of pouch bag packaging in open trays was hitherto possible, it was labour-intensive, not particularly process-safe but space-consuming. By using a cobot from Yaskawa and an automated palletizing system from Profipack, a cycle time of 20 seconds per tray can now be achieved with high process stability and compact design. This solution has been successfully used at the dairy Privatmolkerei Bauer since January 2026.

Toimialat
Elintarviketeollisuus

Asiakasohjelma
Profipack Verpackungsmaschinen GmbH

Tuotteet
HC-sarjan yhteistyörobotit

Since 1887, what is now the privately owned dairy Privatmolkerei Bauer GmbH & Co. KG in Wasserburg am Inn, Bavaria, has been all about milk processing, with continued and growing market success. The company's yogurt, drinking yogurt and cheese specialties are to be found in refrigerated display cabinets nationwide, and for decades they have been leading products in a highly competitive environment.

One of the main cornerpoints of the business has been the continuous development of the portfolio through innovative product and taste concepts. Another is the consistent optimization and automation of production and packaging processes – with the aim of ensuring sustainable quality while relieving employees of physically stressful routine activities.

Picture: The cobot removes the trays from the upstream packer, places them on pallets and independently inserts cardboard intermediate layers.

Automation at the end of the packaging chain

In their latest automation project, the managers of the Privatmolkerei Bauer opted for packaging yogurt in pouch bags – more precisely: the completion of the packaging chain. The focus was on the task of stacking containers already arranged in trays on euro pallets in accordance with shipping requirements. This process step was previously performed manually. “The primary goal was to increase process reliability,” explains Anton Weber, responsible project manager at the Bauer private dairy. He adds: “In addition, the palletizing solution should have a high integration capability into existing processes and be easy to use.”

The main challenge lay not so much the required output of at least three trays per minute, but rather in the fulfilment of certain parameters. Firstly, due to space constraints the system was to be able to operate without a protective fence or additional security devices. Secondly, open-topped trays are used, each containing 40 pouches in ten individual boxes that must not be allowed to slip during handling. Thirdly, the insertion of cardboard intermediate layers was required.

Picture: Private dairy Bauer has been asserting itself on the market for decades with innovative product and taste creations.

Profipack plant concept

As part of a structured selection process, the Privatmolkerei Bauer opted for a solution developed by Austrian Profipack Verpackungsmaschinen GmbH. Founded in 1998, the company specializes in packaging, palletizing, unloading and conveyor technology, as well as intralogistics systems. In particular, it serves the ‘dry sector’ of the food & beverage industry and other sectors.

In addition to its service portfolio and extensive experience in the dairy and brewing industry, Profipack offered the additional advantage of geographical proximity: the company is located in Schwoich near Kufstein in Tyrol, just 70 kilometers from Wasserburg.

In order to fulfil the requirement for a freely accessible system, in this project Profipack implemented a cobot-based solution for the first time. The collaborative robot is designed for safe operation in direct contact with humans, and performs several functions. It removes two trays of ten individual packages from the upstream packer and places them on one of two pallet spaces. Upon reaching the maximum stack height, an automatic change occurs so that the full pallet can be replaced. In addition, the cobot independently inserts cardboard interlayers. The process is currently designed for three different pouch formats or weights, and can be expanded with additional programs if necessary.

Picture: The six-axis HC20DTP features a payload of 20 kg and a working range of 1,900 mm. Switch cabinet and controls are integrated in the base to save space.

Cobot with HRC lightweight vacuum gripping system

As a long-time system partner of Yaskawa, in its first cobot project Profipack Verpackungsmaschinen GmbH decided on a model from this manufacturer: a six-axis HC20DTP with a payload of 20 kg and working range of 1,900 mm. In order to save space, the switch cabinet and control system are integrated into the base.

The cobot models of the DTP series (P for plug & play) feature an adapter flange that has established itself as the de facto standard for connecting peripherals such as grippers. In addition, the media guidance for Ethernet, I/O and compressed air is integrated into the robot arm, thus avoiding interference contours and improving cleanability.

Optimized cable routing enables extended movement radii of the axes and thus increases flexibility in use. Wrist controls are available for programming. These simplify manual learning, as position confirmations can be made directly on the robot.

In the present application, the cobot is equipped with a modular HRC lightweight vacuum gripper developed by Profipack, which accommodates two trays at a time. This increases throughput while stabilizing open trays during palletizing. A slight inclination of the gripper also ensures a secure hold of the packaging.

The individualized security concept for human-robot collaboration was implemented by Yaskawa, who also closely supported the project. Hannes Langreiter, responsible for technical sales and distribution at Profipack, sums up “We received intensive support,” thereby emphasizing the positive effect of the collaboration also on the customer side.

Picture: A central component is the modular HRC lightweight vacuum gripping system developed by Profipack itself.

Summary

The pouch bag palletizing system has been in operation at the Privatmolkerei Bauer since January 2026 and meets the requirements of everyday production. The system achieves a 20-second cycle time per tray with high process stability, and fits seamlessly into the packaging line. The cobot also handles the application of intermediate layers and enables adaptation to different pouch formats through flexible programming.

“The system operates safely and space-savingly without additional protective devices,” summarizes Project Manager Anton Weber. “Furthermore, the solution is robust and suitable for industrial use. Even after several months of three-shift operation, it has proven to be a wise investment decision.” This positive cooperation has already laid the foundations for further joint projects.