End-of-line automation that redefines industrial production
Industrial automation is transforming the way factories produce, package, and deliver their products. A striking example of this transformation is the latest project developed by ESI Robotics: a fully automated detergent production line, entirely robotized and connected, integrating eight robots — divided into 4 robotic packaging cells and 4 robotic palletizing cells, operating in perfect coordination.
The challenge: automating the entire end-of-line process while optimizing space
The client sought a solution that would ensure maximum efficiency and precision, reduce manual labor, and increase production capacity. The challenge was to automate all end-of-line operations, from integrating the client’s filling machines to packaging, palletizing, and wrapping, creating an efficient, flexible, and fully integrated solution.
A particular challenge was the limited space and the need to maintain a forklift circulation area to support the logistics workflow. ESI Robotics designed an elevated box circulation zone to allow normal worker movement and safe operation.
The entire project was executed by ESI Robotics as a turnkey solution, from concept and engineering to integration, assembly, and programming of all equipment and components. The goal was to create a highly efficient automated line, capable of handling different formats and product references while maintaining consistently high performance. The challenge was successfully achieved!
The solution: a fully connected production line
The final line is 100% automated, with 4 robotic packaging cells and 4 robotic palletizing cells, connected through intelligent transport, elevation, and control systems. Integration between robots, filling machines, and supervision software ensures a continuous, optimized flow without interruptions or waste.
Key automated processes:
- Filling machine integration – Coordinates bottle filling to maintain seamless flow with the rest of the line.
- Automatic box forming – Quickly and accurately prepares empty boxes ready for products.
- Pick & Place (handling multiple product references) – Robots place different product references into the correct boxes.
- Packaging – Packages products and closes boxes automatically, ensuring speed and consistency without manual input.
- Labeling – Applies labels on units or boxes, ensuring traceability and compliance.
- Box elevation and transport – Safely moves boxes between packaging and palletizing stages.
- Robotic palletizing – Arranges boxes on pallets in stable, transport-ready stacks, with patterns adapted to each product.
- Automatic pallet dispenser and transport – Supplies empty pallets to palletizing cells without manual handling.
- Interlayer handling with multifunctional gripper – Places separators between box layers while manipulating products.
- Automatic transfer of complete pallets – Moves fully loaded pallets from palletizing to wrapping zones, collecting pallets from all cells.
- Pallet wrapping – Secures pallets with stretch film for safe storage and transport.
- Monitoring and control via Digital Twin – Tracks the line in real time, simulates scenarios, and optimizes every production step.
The Digital Twin advantage
The integration of a Digital Twin was a key technological milestone. This virtual replica allows real-time monitoring of every cell, anticipates anomalies, tests improvements, and ensures the system runs at peak efficiency.
With this digital insight, the client gains a complete overview of the production line, enabling parameter adjustments, process optimization, and data-driven decisions, all remotely and intuitively.
Results: productivity, precision, and connectivity
The fully automated line delivered measurable benefits:
- Increased productivity with continuous, uninterrupted flow;
- Reduced errors and downtime;
- Optimized use of space and resources;
- Full process control through digital integration;
- Enhanced operator safety and ergonomics;
- Industry 4.0 readiness with real-time data and connectivity.
This project demonstrates how industrial automation and robotics can transform complex operations into efficient, sustainable, and fully controllable processes.
For ESI Robotics, this project represents more than an automated line. It’s a step forward in building the smart factory, where robotics, digitalization, and real-time data set new standards for efficiency and reliability.
Industrial automation is no longer just a productivity tool — it is now the core of industrial innovation, and this project is a clear example of that evolution.
Looking to automate your production? Contact us today!
