Reducing repetitive manual handling through smart automation
LG Motion has successfully supplied and installed an automated palletising solution at Farécla’s UK manufacturing facility, supporting their continued investment in safer, more efficient production.
At the end of Farécla’s production lines, finished cartons weighing between 6 kg and 17 kg were previously stacked manually onto pallets, requiring continuous lifting and handling throughout the day. This process had been identified as a higher-risk, repetitive task.
To address this, LG Motion designed and delivered a complete palletising system using a Techman TM25S collaborative robot, integrated with an OnRobot VGP20 vacuum gripper and powered by OnRobot’s D:PLOY software.
The system now carries out pallet stacking automatically within a guarded enclosure, removing almost all repetitive lifting, twisting and strain from the operation.
Supporting operators on the line
The introduction of automation has allowed Farécla’s team to move away from physically demanding palletising duties. Instead, operators can focus on line management, material flow and quality checks, while the robot handles the repetitive lifting.
This has resulted in smoother production, fewer interruptions at the end of the line and longer continuous run times.
Improving consistency and efficiency
The automated solution delivers consistent, repeatable pallet builds, improving load stability during storage and transport while reducing the need for re-handling.
LG Motion engineered the system to fit within the available footprint and accommodate multiple product formats, ensuring flexibility as production requirements evolve.
Built for future demand
The installation enables Farécla to increase throughput without increasing physical workload on staff. It forms part of a wider approach to improving working conditions while maintaining reliable supply to customers.
A practical step forward in automation
This project highlights how targeted automation can remove high-risk manual handling tasks while enhancing productivity and consistency.
LG Motion continues to support manufacturers with tailored robotic solutions that improve day-to-day operations, helping teams focus on process control, quality and output while automation handles repetitive tasks.
