Challenges
  • The system’s machinery is outdated and not up to the global standard for automation.
  • Low productivity, uneven product quality, and errors due to manual production processes.
  • A diverse range of products in various sizes, shapes, and designs.
  • Lack of integrated quality management and monitoring systems.
Keys to Success
  • Implementing a series of advanced technologies: Delta Robots, Case Packers, Palletizing Robots, and Automated Guided Vehicles (AGVs) to create a fully automated, flexible production line suitable for various products.
  • ETEK’s experience in project deployment and technology integration.
  • A global network of partners
Results
  • Successful development of a fully automated packaging production line.
  • Capacity of up to 180 products per minute.
  • Operates continuously for 22 out of 24 hours.
  • Productivity increased by 60%.
  • 100% of products meet standards post-production.
  • Ensures 100% labor safety.

Automation in Consumer Goods Manufacturing

Unilever is one of the world’s largest consumer goods companies, owning numerous well-known brands and a global network of manufacturing plants. In Vietnam, Unilever has two significant factories located in Bac Ninh and Cu Chi, aiming to meet domestic market demand.

However, the production systems here are still primitive and unsynchronized compared to Unilever’s factories in other countries and regions. The reliance on manual labor has led to unstable product quality, defects, and a lack of strict control before the products are released to the market. Besides, the low production productivity poses challenges in meeting the growing market demands. This situation also occurs at Unilever’s factories in Indonesia and the Philippines.

As a leading provider in Vietnam specializing in comprehensive automation solutions, ETEK has had the opportunity to work with Unilever’s factories in Vietnam, Indonesia, and the Philippines, proposing optimal solutions to overcome production limitations while enhancing productivity and product quality.

Comprehensive Automation Solutions

Understanding the needs of the factories and leveraging our strengths to provide comprehensive automation solutions, ETEK confidently collaborates with clients to develop modern consumer goods production lines that meet global standards. We bring specific solutions to address each production difficulty, helping to optimize processes and enhance operational efficiency.

Product Handling System – Delta Robot

The high-speed system developed by ETEK is ideal for automatically supplying products like bottles, jars, cans, pouches, and packs into the filling system or feed. Capable of handling up to 180 products per minute, the system includes:

  • Bottle supply system and plastic tray conveyor system.
  • Delta robot for bottle handling.
  • Camera system to check and reject trays without products back to the navigation conveyor.
  • Conveyor system for bottle return.
  • Conveyor system for moving bottles to the filling machine.
  • Filling machine system.
  • Bottle capping machine system.

Case Packing System (Case Packer)

The packaging and case packing steps demand absolute accuracy in quantity and method. To meet the stringent requirements of the clients, ETEK has developed a Case Packer system with superior features:

  • Capacity: Achieves 15 product cases per minute, enhancing packing and production speed.
  • Efficiency: Operates continuously across three shifts, capable of transporting goods up to 40kg with a reach of 2300mm.
  • Difference: Utilizes 6-axis robot technology, ensuring precision. With this system, factories can avoid potential consequences of incorrect packaging, protect brand reputation, and increase operational efficiency.

Palletizing and Wrapping System

The transportation of consumer goods demands fast speeds and absolute safety. ETEK’s palletizing robot system is designed to meet these requirements, including optimally

  • Automatic pallet supply system with a capacity of 10 pallets.
  • Roller conveyor.
  • Weighing conveyor.
  • RGV conveyor.
  • Wrapping machine.
  • Robot. Benefits:
  • Fully automated palletizing process.
  • Operates continuously for up to 22 hours a day.
  • Flexible in handling different types of pallets.
  • Reduces heavy labor for workers, enhancing workplace safety.
  • Increases the durability and safety of packages during transportation.\

Achieved Results

After implementing comprehensive automation solutions from ETEK, the consumer goods manufacturing plant has achieved outstanding results. Production productivity has significantly increased thanks to robotic systems, which quickly and steadily meet market demands.

Accuracy in packaging and case packing has been notably improved, minimizing common errors, thus protecting brand reputation, enhancing product quality before reaching consumers, and optimizing the supply chain. Additionally, reducing dependence on manual labor saves costs and creates a safe, modern working environment that meets international standards.

These results affirm the factory’s vital transformation and readiness to compete globally.