Tray handling connects individual process steps within a production line and ensures a controlled and reliable product flow. Products can be automatically removed from trays, placed into trays, transported between machines or buffered as required.
RoboMat develops tray handling solutions for pharmaceutical and medtech applications that can be flexibly integrated into existing production environments or used as independent systems. Different product and tray formats, changing production requirements, and reliable transfer between assembly, inspection, labeling and packaging are considered from the outset.
Our tray handling solutions are suitable for a wide range of pharmaceutical and medtech products and can be adapted to different product geometries and tray formats. This allows multiple product variants to be processed on the same machine platform.
Typical applications include:
Depending on the process, products are removed from trays, placed into trays or transferred between different process steps within a production line.
Depending on the process requirements, products are automatically loaded into or unloaded from trays. The systems handle both the products and the supply, separation and further handling of the trays.
Different product and tray formats can optionally be processed on the same platform. Tool-free format changeovers reduce changeover effort.
Tray transport systems connect individual process steps and ensure a controlled tray flow throughout the production line. Loaded or empty trays can be transported between different stations, buffered and supplied to the respective process as required.
Typical applications include connecting a filling or final assembly line with a downstream packaging machine. At the upstream process, trays are presented for loading, then transported and buffered if required. At the downstream process, they are presented again to allow safe product removal.
Integrated buffers decouple different process cycle times and can compensate for short interruptions. Optional infeed and outfeed stations can be integrated for manual tray loading or removal.
Depending on the process, product flow and required level of automation, different tray handling concepts can be used. RoboMat combines proven platforms with customer-specific functions. The range extends from compact de-trayers for direct integration into packaging lines to automated solutions supplied from Euro pallets or pallet trolleys and tray transport systems connecting multiple process steps.
The Compact De-Trayer is designed for direct integration into packaging machines or cartoners. Compact L-, U- or T-shaped layouts allow the system to be integrated into existing lines even where space is limited.
Trays are automatically supplied, separated and presented at the unloading position. Vision systems can detect the position and orientation of the trays, supporting precise and reliable product handling. Depending on the project, the system can be controlled by the packaging machine or by its own RoboMat control system and software.
For greater autonomy, tray stacks can be processed directly from Euro pallets or pallet trolleys. The trays are automatically destacked and supplied to the process.
An integrated intermediate buffer ensures that production can continue during pallet or trolley changes. Empty trays can then be restacked compactly or, depending on customer requirements, compacted. Tool-free format changeovers enable different tray and product formats to be processed with minimal changeover effort.
Tray transport systems connect, for example, filling or final assembly with a downstream packaging machine. At the upstream process, trays are presented for loading, then transported and buffered if required. At the downstream process, they are presented again for product removal.
Optional infeed and outfeed stations can be integrated, allowing trays to be manually introduced into or removed from the automated material flow.
Product Handling within the Tray
In addition to handling the trays themselves, safe and precise product handling is a key part of the solution. Depending on the application, products are removed from defined tray positions or placed precisely into them.
Depending on the product, vacuum grippers or mechanical gripping concepts such as parallel or centric grippers are used. As standard, an expanding gripper can automatically move between two different pitch distances. This allows products to be picked from one tray pitch and transferred to a different pitch or downstream process.
Each gripping operation is monitored to verify that a product has actually been picked. Empty picks can therefore be detected and handled in a controlled manner.
Vision-Guided Handling and Process Control
Vision systems can detect the position and orientation of products within the tray and transmit the position data directly to the handling system or robot. This enables products to be picked and placed precisely and gently, even when their position deviates from the nominal position.
The system can also verify whether all designated tray positions are correctly occupied and whether any products remain in the tray or outside their designated positions after unloading.
Flexible for Different Formats
Tool-free format changeovers and adaptable gripper concepts enable different product geometries, tray formats and pitch distances to be processed on the same system.
RoboMat tray handling systems can be designed as directly integrated machine modules, as independent machines within a production line or as autonomous tray handling cells, depending on the process requirements.
Directly Integrated Machine Module
Compact systems such as the Compact De-Trayer are integrated directly into a packaging machine or cartoner. Control and operation can be handled entirely by the upstream or downstream machine.
Independent Machine within the Line
The tray handling system has its own control system and HMI while remaining directly connected to upstream and downstream equipment. Interfaces, material flow and buffering are coordinated with the overall production process.
Autonomous Tray Handling Cell
Trays or tray stacks are supplied to the system and discharged again after processing. Within the cell, processes such as inspection, product handling or re-traying between different tray types can be performed.
Line Communication
Control signals, machine states, recipe data and process signals can be exchanged with upstream and downstream equipment and coordinated across the overall production process.
Tray and Product Inspection
Trays can, for example, be uniquely identified using defined color markings. A color sensor verifies that the correct tray type is provided for the selected product or format. Vision systems can additionally verify whether designated positions are occupied, whether a tray has been completely emptied or whether products are located outside their intended positions.
Monitored Product Handling
Each gripping operation is monitored to verify that a product has actually been picked. Empty picks can therefore be detected. Vision-based position detection additionally supports precise gripping and reduces the risk of mispicks or product damage.
Controlled Process Environment
A closed machine enclosure serves not only to ensure machine safety. It also prevents uncontrolled intervention in the automated process, helping to maintain defined process sequences and reduce the risk of unintended or manual interference with the product flow.
RoboMat tray handling systems are designed for use in regulated pharmaceutical and medtech production environments. Machine design, control systems and documentation are adapted to the project-specific GMP requirements.
Die Tabletten-Trays waren in bis zu 20 Lagen in Shoe-Boxen verpackt, wobei die beiden Lagenniveaus deutliche Positions- und Winkeltoleranzen aufwiesen. Das Entnahmesystem musste diese Variabilität sicher kompensieren und die Trays zuverlässig vereinzeln. Zusätzlich sollte die Anlage Shoe-Boxen direkt aus Trolleys mit mehreren Aufnahmefächern automatisch übernehmen.
Are you planning to load or unload trays, automate tray transport, or connect multiple process machines? Contact us for an initial technical assessment of your tray handling application.
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