At a glance
Customer: Turkish water-soluble fertilizer producer
Problem: Manual weighing and stacking limited output and caused weight drift
Solution: We delivered a linked packaging train: automatic bag placing, net-weight filling, checkweighing with rejection, robotic palletizing with 6 stored patterns, and stretch wrapping. The robotic palletizer was chosen specific...
Result: Packing labor cut by 70%
| Customer type | Turkish water-soluble fertilizer producer |
| Industry / project type | Автоматизация фасовки |
| Capacity | 600 bags/h |
| Country / region | Türkiye |
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Why the project happened
A Turkish WSF producer with growing export orders needed to replace a manual packing operation with a fully automatic bagging, checkweighing and palletizing line, while keeping weight compliance for regulated EU-adjacent markets.
What the customer faced
These are the specific issues the project was built to solve.
- Manual weighing and stacking limited output and caused weight drift
- Export customers required tight weight tolerance and stable pallets
- Frequent bag and pallet pattern changes slowed the line
- Labor cost and turnover made the packing department a bottleneck
- No production data on output, rejects or downtime
Limits we designed around
Real projects are never ideal. These constraints shaped the configuration and delivery plan.
- 600 bags/h target with 5-25 kg bags
- Multiple bag patterns required for different export customers
- Existing building space with defined conveyor path
- Integration with an existing bagger was required
Why we configured it this way
We delivered a linked packaging train: automatic bag placing, net-weight filling, checkweighing with rejection, robotic palletizing with 6 stored patterns, and stretch wrapping. The robotic palletizer was chosen specifically because the customer changes bag and pattern frequently. A line PLC with recipe storage gives the producer output, reject and downtime data for every shift.
How it was delivered
From requirements confirmation to commissioning - the key nodes of this project.
Interface audit
Audited the existing bagger, conveyor heights, bag types and output.
Line design
Simulated the 600 bags/h flow including buffers and reject path.
Fabrication
Built and tested the robotic palletizer, checkweigher and conveyors.
Installation
Integrated with the existing bagger with minimal production downtime.
Commissioning
Verified speed, weight compliance and 6 pallet patterns with the customer's bags.
Difficult points and how we solved them
Retrofit to existing bagger
Interface audit before design; matched conveyor heights and PLC handshake.
Weight compliance
Net-weight filling plus checkweigher with reject gate; 20-bag audit at acceptance.
Frequent pattern changes
Robotic palletizer with 6 stored patterns and quick-change gripper.
What changed after delivery
Verifiable changes from this project. Where specific figures are confidential, we state the direction and the evidence.
- Packing labor cut by 70%
- Export-grade weight compliance with documented audits
- 6 pallet patterns switchable in minutes
- Shift-level output and reject data available to management
Project outcome
Труд фасовки сокращён на 70% при соответствии веса для экспорта.
What similar customers can learn
For producers with export compliance requirements, this case shows that packaging automation ROI depends on matching the machine to your bag types and changeover frequency. If you change patterns often, a robotic palletizer pays for itself faster than a fixed high-level unit.
Questions from similar projects
What speed is realistic for a robotic palletizer?
Can the line integrate with my existing bagger?
What data does the line produce?
Your conditions, our configuration
The fastest way to a useful answer is to compare your project against this one: raw materials, capacity, bag size, site and destination.
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