Endoline Robotics has transformed operations at a major UK cheese processing plant with the installation of a £1.27 million fully automated case packing and palletising line—delivering a robust solution to ongoing staffing shortages, extreme working conditions, and rising production demands.
Faced with the challenge of maintaining high output in a cold, labour-intensive environment, the cheese processor partnered with Endoline to overhaul its end-of-line operation. Within the site’s existing 21 m x 11.5 m footprint, Endoline designed and installed a compact, high-performance system that modernised processes without the need for expansion. Crucially, the installation was two-phased, allowing uninterrupted production.
The impact has been significant – replacing the repetitive manual tasks previously carried out by over nine operators while delivering a sharp increase in performance and productivity. Workforce safety and morale improved dramatically, and the system also introduced a new level of precision and consistency to every packed case of cheese.
Supplying over 100,000 tonnes of grated cheese annually to wholesalers, food service operators, and pizza chains, the company had long faced challenges in retaining staff due to the physical demands of the job and the plant’s constant 5°C environment.
Precision engineering in a compact space
Previously reliant on a manual Lazy Susan-style packing station, the site was hindered by slow throughput and frequent product damage. Manual handling of gas-flushed pillow packs often led to nitrogen leaks, inconsistent stacking, and high return rates.
Endoline Robotics delivered a fully integrated, high-speed automated line within the tight constraints of the existing layout.
Every centimetre of space was maximised to accommodate a sophisticated setup that includes three Endoline fully automatic case erectors, three FANUC Delta robots with rotating PIAB vacuum grippers, three Endoline case sealers, three labelling stations, three checkweighers, and an integrated stretch wrapper and pallet labeller.
A central multi-tasking FANUC M-410-iC robot manages palletising across all three lines. Using barcode scanners and rising pallet stacks to determine position, the robot efficiently services three pallet stations. This smart motion planning has saved valuable space and equipment costs while cutting 5–6 seconds off every pallet changeover cycle, boosting efficiency.
Delicate handling, high-speed throughput
Cheese pillow packs, ranging from 1kg to 6kg, are conveyed via multi-level systems from production to the loading cell. At the infeed, Endoline’s automatic case erectors prepare each case before the Delta robots take over.
Designed for chilled environments, the robots’ rotating suction-cup end effectors delicately rotate each pack 90° and place them into consistent formations. This smooth, controlled motion has eliminated pack ruptures, significantly reducing waste.
Filled cases are sealed and labelled using a GSI1-compliant Markem-Imaje print-and-apply system, checkweighed, and passed to the palletising zone via a central trunk conveyor.
Operating six days a week, 24 hours a day, the system processes up to eight cases per minute per line—delivering a high-speed, hands-free end-of-line solution.
Built for the future
With capacity to process and palletise up to 28,800 product cases every 24 hours—more than double the previous manual output—the facility has become a benchmark for cold-environment automation. Each case is handled with repeatable precision, while overall throughput and quality assurance have reached new heights.
Beyond speed and efficiency, automation has delivered lasting operational resilience. Packing bottlenecks have been eliminated, and former manual staff have been reallocated to higher-value roles, reducing cold exposure and improving morale.
Andrew Yates, Managing Director of Endoline Automation, commented: “This installation is a true reflection of Endoline’s engineering expertise—designing a highly efficient, fully automated solution that not only meets the challenges of operating in cold environments but also maximises every inch of available space. It’s a smart, innovative setup that’s enabling our customer to work more productively than ever within a compact footprint.”
