Optimizing Primary Packaging Through Flexible Gripping Systems

The packaging sector is transforming at a rapid pace to address increasing needs for speed, flexibility, and security. Secondary and tertiary packaging have been extensively automated, yet primary packaging continues to pose distinct challenges, particularly when handling delicate and irregular items like eggs, bakery, and candies. They cannot endure great force, uneven pressure, or contamination and thus cannot be handled conventionally. Most facilities still employ manual handling despite the susceptibility to errors, fatigue, and breakage. However, mechanical grippers traditional in nature usually lack the flexibility and delicacy that sensitive products require.

This is the gap between efficiency and delicate care where higher-level vacuum-based gripping technologies like the Finger gripper mGrip and the Schmalz FG-X suction cups set a new standard for primary packaging solutions. Both are configured to deal with industry-specific requirements along with maintaining hygiene, safety, and efficiency on contemporary packaging lines.

Primary packaging is always more intricate than secondary or tertiary processes since the product being manipulated is usually fragile, perishable, and sensitive to influences. For instance, eggs are required to be handled without trays in some processes like quality inspection and grading. Even slight cracking during handling may lead to product loss, customer complaints, and compliance risks. In a similar way, baked items like croissants or muffins become deformed when subjected to mechanical stress, and chocolates or confectioneries are prone to scratching or breaking.

One other major challenge is hygiene. In both food and pharmaceutical packaging, any contact surface will need to meet strict requirements, like FDA standards, to prevent contamination. Traditional gripping means, especially mechanical fingers or non-certified suction cups, tend not to be up to the task. On top of that, add the pressure of shrinking product life cycles, high production expectations, and labor shortages, and the call for sophisticated, adaptable solutions becomes imperative.

The Vacuum Handling Application in Fragile Product Packing

Vacuum handling provides a distinct benefit in packaging operations: it allows for safe yet delicate lifting independent of mechanical force. Through distributing the gripping pressure uniformly over the product surface, vacuum technology reduces stress points, cracking, or deformation risk. Additionally, contemporary vacuum cups and modular gripping systems have the capability to adjust to various product geometries without the need for lengthy changeovers. It makes switching between product SKUs rapid, thus lowering downtime and enhancing throughput.

At Schmalz, the emphasis has been on creating vacuum gripping solutions that are not only reliable in terms of product transfer but also address the hygiene and efficiency requirements of the packaging industry today. Two innovations in this area are mGrip and FG-X suction cups.

mGrip: Modular Flexibility for Diverse Packaging Needs

Finger Gripper mGrip

The mGrip technology is a soft-gripping, modular system that employs food-grade, elastomeric fingers to flex and adjust to products of different shapes and sizes. In contrast to hard grippers, mGrip adjusts to the product geometry and is especially well-suited for irregularly shaped products like bakery items, candy, or delicate snacks.

The mGrip modularity enables packaging plants to tailor gripping systems to their product line. From a simple single-row egg transfer system to a multi-finger system for baked goods, the system can be easily reconfigured without having to redesign it totally. This flexibility minimizes capital investment and facilitates manufacturers’ ability to adapt to changing packaging needs.

From a technical standpoint, mGrip can easily be integrated into high-speed robot packaging lines. Its light weight accommodates fast cycle rates, and the utilization of food-grade materials maintains regulatory compliance with regard to hygiene. Together, this adaptability, regulatory compliance, and speed tackles several issues at once, making it an asset in current packaging processes.

FG-X Suction Cups: Delicate Handling of Fragile Products

Where mGrip is better suited to handle irregular products, there are some applications where suction handling based on direct contact with fragile items is required. FG-X suction cups are used specifically for that. Made of FDA-grade silicone, FG-X cups are oil-, fat-, and cleaner-resistant, and hence ideal for use in hygienic areas and regular washdowns.

FG-X Suction Cups

It is the FG-X’s special geometry that differentiates it. Featuring a cross-shaped sealing lip and a flexible contour, it can be configured to fit curved or irregular surfaces like eggs or soft fruits. This allows for direct egg handling without trays — an important boon in primary packaging, grading, or quality inspection. The even distribution of vacuum ensures the product is securely held without focal points of stress concentration, lessening the likelihood of cracking or breakage.

FG-X cups are also built to last with continuous usage. Their strong material withstands long service life even in harsh packaging conditions, thereby minimizing downtime and maintenance expenses. Notably, the even surface contours reduce residue accumulation, allowing for both hygiene and rapid cleaning cycles.

Applications Beyond Eggs

Though egg handling is among the most prominent application examples for FG-X suction cups, there are numerous other areas where they can be applied. They find application in bakery lines where croissants, bread rolls, or muffins need to be handled directly without deformation. In confectionery, they allow safe transfer of pralines, chocolates, and dainty sweets without scratching or cracking of the surface. The technology can also be applied to the pharmaceutical industry, where blister packs or sensitive items require contamination-free handling.

In all of these uses, FG-X suction cups deliver the balance between secure holding and sensitive handling that conventional systems find difficult to accomplish.

Productivity and Efficiency Gains

The integration of mGrip and FG-X solutions onto packaging lines is immediately clear in terms of productivity gains. Automated handling minimizes reliance on manpower, eliminating the potential for fatigue, variability, and human error. The versatility of the systems enables quick adaptation to multiple products, with minimal downtime during changeovers. Concurrently, the secure yet gentle handling minimizes product loss due to breakage, directly enhancing yield.

From a safety of the worker point of view, automation eliminates physical strain and repetitive injury due to manual handling of delicate products. For manufacturers, this equates to a more stable workforce, increased morale, and fewer accidents.

Future Outlook

With the packaging sector increasingly going towards automation and Industry 4.0 integration, the need for intelligent, flexible, and hygienic handling solutions will keep rising. Solutions like mGrip and FG-X suction cups are not incremental advancements — they are a paradigm shift in the manner in which delicate products can be packaged in high volumes. By blending adaptability, compliance, and delicate handling, such solutions pave the way for more efficient, sustainable and future-proof packaging lines.

Author:
Mr. Jayesh Marane
Industry Manager – Packaging
 

Contact for questions
Schmalz India Private Limited
Marketing Department
EL 38, J Block, MIDC, Bhosari, Pune 411026
T: 020-69115500
marketing@schmalz.co.in