Bakeries that have capitalized on technological advancements in production equipment, particularly those associated with pan handling systems, are surely reaping their rewards. Automated pan handling systems efficiently handle multiple product changeovers, reduce downtime and increase throughput. Units can be customized to fit a variety of space requirements and production needs. Pan handling systems also are designed to maximize pan life.

“The robotic pan handling systems are faster, more consistent, quieter and able to handle a larger array of pan types and weights versus the conventional stackers/unstackers, which helps reduce maintenance and sanitation issues,” says Ken Mentch, sales engineer, Workhorse Automation Inc., Oxford, Pa.

Some of the most significant benefits associated with automated pan systems are those afforded to line operators. Workers sustain fewer injuries by not having to manually push pan trucks around the plant. In addition, automated units provide operators with a system interface for managing pan stacking, unstacking, pan storage retrieval, product changeovers, depanning, maintenance and sanitation.

Efficiency engineering

Improvements in pan handling systems give bakers the flexibility to run multiple types of products without incurring downtime. Pan handling systems that have the capability of handling changeovers with fewer line stoppages improve throughput.Charles Gales, manager, automation sales, Weldon Solutions, York, Pa., explains how increased throughput can be achieved:

• Robotic pan stackers move more smoothly than fixed path pan stackers and unstackers by handling multiple pans at one time. This gentle handling results in fewer jams.

• Robotic systems can be designed with potential jam points at waist height rather than overhead.

• Automatic pan changeovers ensure the least amount of time is spent between production runs.

• Continuous improvement in the programming and operation of automated pan handling systems results in fewer faults and reduced downtime due to maintenance.

Machines equipped with computer-based vision systems contribute to improved process efficiencies. “Our latest Automatic Pan Storage & Retrieval Systems (AS/RS) have been improved for speed with the use of lasers for distance measuring,” Mentch says. “The new speeds achieved on the AS/RS allow one system to handle a simultaneous changeover of lids and pans on two separate production lines.”

Maximizing space

Some bakers may avoid investing in mechanized equipment because of limitations posed by their processing area's footprint. Fortunately, designers of pan handling systems have taken space availability into consideration by creating units that vary not only in the width of pans that can be moved at one time, but also in stacking height.

For instance, Capway Systems offers a range of robotic units, from a single-arm robot with a 3-ft. wide mechanical gripper to those that can handle up to 30 ft. of pans at one time. All are specifically engineered for production rate, pan size and variety of products, notes Frank Achterberg, president of the York, Pa.-based company. The small, single-arm robot is basically a replacement for the conventional magnetic stackers and unstackers where pans are manually stacked on or off a truck, or onto a secondary system.

Achterberg estimates the space required for a small system at about 25 ft. by 14 ft., which is comparable to the area used for a standard stacker/unstacker. A large system that holds a variety of pan styles in higher stack heights may require a footprint that is 35 ft. wide by 100 ft. long.

A robotic system with mechanical grippers can actually pick up an entire horizontal row of pans and stack them vertically. “It's all done within a confined area,” Achterberg explains. “Once the pans are placed within a unit, they don't have to be moved again, so there's no secondary equipment or personnel required. You can also safely stack higher. For instance, the stacks could be up to 96 in. high instead of 40 in.”

Emphasis also has been placed on the use of multi-level storage and retrieval systems, which capitalizes on the availability of vertical cube space within bakeries, Mentch notes. Maximizing unused vertical space allows bakeries to better use valuable production floor space.