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The Robotic SUBTA systems have also created unexpected improvements in the manufacturing process. The company noted a net reduction of 1/2 percent of scrap, adding 500,000 bottles per year to its output simply by virtue of not dropping the bottles. Since fewer products need to be reground, the company also saves money considering the cost to run the regrind machines has gone up greatly as the cost of oil increases. In addition, this reliable process has cut the employee bending movements by 50 percent.

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Everything in the plant runs much more smoothly. More bottles are being produced, but the pace seems slower since there was a reduction in complexity in the system,” said the plant manager. “We have seen a reduction in the commotion and activity since employees can now work at a constant pace and succeed without as much physical effort. We also have a greater chance to understand the bottlenecks in the manufacturing process. We are reviewing to see where we can make an economic justification for adding automation,” said the plant manager. “We chose the ones that are simple to execute first that run one mold all day, as well as the systems with the highest stress strain or ergonomic safety issues. We are looking for future automation as soon as we can.
Motion Controls Robotics’ created the Robotic SUBTA system, a pre-engineered robotic system designed for PET blow-molded bottle handling. The system uses different robotic units depending on the type of machine that is being unloaded. The Robotic SUBTA system grabs and sets the bottles on a conveyor, standing up, acting as a takeaway unit. The system provides increased throughput due to high reliability and uptime and cycle times faster than most mold machine rates. The Robotic SUBTA system also requires a minimum of floor space, a high priced commodity in a manufacturing facility.
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The company contacted Motion Controls Robotics to ask them to help develop a solution that would automate its bottle take out process and alleviate its safety and ergonomic issues due to repetitive stress injuries. They also wanted to create a solution that would reduce scrap, which ultimately would help increase sales without having to produce more product than it did in the past.
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