Boost Packaging OEE with Industrial Manipulators | Vietmani

The instant noodle manufacturing industry always demands extremely high packaging rates and continuous operation to meet massive production volumes. However, production lines often encounter a major "bottleneck" at the loading stage: packaging film rolls (BOPP/CPP) are very heavy, ranging from 20 kg to over 150 kg. Completely manual lifting and alignment of these film rolls not only disrupts the packaging machine's speed but also poses a risk of serious musculoskeletal injuries to workers.

To thoroughly solve this problem, the application of Industrial Manipulators is becoming an essential investment, helping factories break through productivity limits and build a safe, professional working environment.

Challenges in the manual film roll loading process

In modern instant noodle production lines, high-speed packaging machines (such as BOSS450 or DS-350X) can process hundreds of packages per minute. However, this speed becomes meaningless if the input-loading stage stalls. Maintaining the method of manually carrying and installing film rolls reveals 4 core risks:

Imminent risk of occupational injuries (MSDs)

Multi-layer BOPP/CPP film rolls used in instant noodle packaging typically weigh from 20 kg up to over 150 kg. Workers having to constantly bend, twist, and use muscle strength to lift, carry, and align the film roll onto the machine shaft pose a tremendous risk. In the long run, this operation is the main cause of musculoskeletal disorders (MSDs) such as herniated discs and spinal degeneration, directly threatening workers' health.

Decline in Overall Equipment Effectiveness (OEE) due to Downtime

Time is money in mass production. Manually replacing a film roll requires the coordination of 2-3 workers and consumes a lot of time to align the film core to fit the shaft. This slow operation prolongs the downtime of the packaging machine, disrupts the production rhythm, and drags down the Overall Equipment Effectiveness (OEE) index of the entire factory.

Material waste and scrap risks

Packaging film is very susceptible to physical damage. When carried by hand or using rudimentary tools like chain hoists and straps, the risk of slipping or bumping is very high. Just a single scratch, a dent in the paper core, or telescoping due to improper carrying can turn an expensive film roll into scrap, causing significant material waste.

A tough problem in human resource management

The heavy, arduous, and hazardous nature of the loading job keeps the turnover rate consistently high. Factory managers constantly face the pressure of recruiting and retraining new workers, causing organisational disruptions and consuming operational costs.

Industrial Manipulator: A breakthrough solution for instant noodle packaging machines

To thoroughly resolve the risks of manual methods, the Industrial Manipulator was created and has become the new standard in large-scale food manufacturing plants. Not simply a conventional hoist or winch, the industrial manipulator is a sophisticated mechatronic/pneumatic system designed to interact directly and safely with humans in confined spaces.

Handling experience with "Zero Gravity" technology

The heart of a modern industrial manipulator system is the auto-balancer technology, also known as the "Zero Gravity" state. Unlike having to continuously press up/down buttons like using a hoist, the pneumatic logic system inside the manipulator automatically calculates and precisely compensates for the weight of the packaging film roll.

As a result, the gravity of a 50 kg or 100 kg BOPP/CPP film roll is completely neutralised, shifting into a suspended state in space. The operator now only needs to use an extremely small pushing force (just a few newtons) with one hand to freely lift, lower, pull, push, and rotate the film roll to the exact shaft position of the packaging machine smoothly and accurately to every millimetre.

Diverse gripper mechanisms

A specific characteristic of instant noodle film rolls is that they are easily scratched, torn, and torn. Therefore, the end-effector of the manipulator is specially designed to absolutely protect the material:

• Expanding Mandrel Technology: This is the most optimal solution for film rolls. The metal shaft of the manipulator penetrates the paper/plastic core of the film roll, then the pneumatic system pushes the expanding jaws out to press firmly against the inner wall. This mechanism operates from inside the core, completely avoiding contact with the printed film surface, eliminating 100% of scratching risks and telescoping.
• External gripping with rubber padding: Applied to film rolls with specific designs that cannot be core-gripped, the cylinder system will clamp from both sides of the film roll with a safely limited pressing force, ensuring the core is not dented.
• Vacuum Lifter: Uses specialised suction cups to adhere to the curved surface of the film roll, suitable for lifting film rolls from pallets onto carts.

Flexible integration into any factory space

Depending on the layout of the instant noodle production workshop, the manipulator system can be designed as a column-mounted type with a wide working radius (up to 4000mm) to serve multiple packaging machines simultaneously, or an overhead-mounted type sliding on KBK aluminium rails to fully optimise floor space without obstructing forklifts or worker aisles.

=> Read more: KBK-Monorail Suspension System vs Rigid Column Manipulator – Which is the solution for you?

Outstanding benefits of applying industrial manipulators

Investing in an industrial manipulator system is not merely purchasing mechanical equipment, but a comprehensive solution to upgrade the production process. The benefits it brings can be directly measured through the factory's operational metrics:

Increase loading speed, break through the OEE index

With weightless handling, the time to lift a film roll from the pallet, move it, and accurately install it onto the packaging machine's shaft is significantly shortened (often reduced to 1/3 of the time compared to manual labour). Minimising downtime during each roll change helps high-speed packaging machines maintain a continuous operating rhythm. Consequently, the Overall Equipment Effectiveness (OEE) index of the entire line is noticeably improved.

Ideal ROI, long-term cost savings

According to automation investment evaluation reports, the ideal return on investment (ROI) time for an industrial manipulator system in the packaging industry typically falls between 12 and 18 months. These savings come from cutting medical costs due to occupational accidents, minimising the number of workers required for the loading stage, and especially reducing the scrap rate (torn film, damaged cores) caused by handling errors.

Creating an Ergonomic working environment

By bearing 100% of the film roll's weight, the industrial manipulator eliminates the risks of musculoskeletal disorders (MSDs) for workers. Heavy labour is transformed into light control operations. This not only helps factories strictly comply with international occupational safety standards (like OSHA) but also helps retain workers, solving the problem of labour shortages and turnover.

Meeting strict standards for food hygiene and safety

The instant noodle production environment demands very high hygiene standards. Modern manipulator systems can be customised with stainless steel options (304 or 316) for direct contact areas or the entire machine body. The equipment surface is polished, dust-resistant, and easy to wash down and clean, fully meeting the most stringent cleanroom and food safety standards.

Advantages of Vietmani Industrial Manipulators

When deciding to invest in an industrial manipulator system for instant noodle packaging lines, synchronisation and customizability according to actual factory conditions are prerequisite factors. With ISO 9001:2015 certification, Vietmani is proud to provide optimal solutions with exclusive advantages:

• Exclusive Patent Ownership: Vietmani is the only entity in Vietnam to be granted a patent for automated lifting manipulators. The core Auto-balancer - Zero gravity technology (Patent No. 36603) allows the system to automatically balance the load without complex button operations, bringing a smooth, precise, and absolutely safe lifting experience.
• Powerful HA-Series product line: Vietmani's HA-Series pneumatic industrial manipulators are specially designed for heavy industrial environments. With an impressive load range of up to 1200 kg and a wide working radius of 4000 mm, the equipment is more than capable of meeting the loading requirements for super-heavy BOPP/CPP composite film rolls into any current high-speed packaging machine.
• Mastering Technology - Tailor-made to requirements: Manufactured directly at the factory in Phung Xa Industrial Park (Thach That, Hanoi), Vietmani's engineering team is capable of surveying and "tailor-making" various types of grippers – especially expanding mandrels – to perfectly fit the film roll dimensions and the customer's actual workspace.
• 24/7 After-sales service: The advantage of a domestic manufacturer allows Vietmani to provide lightning-fast warranty, maintenance, and parts replacement services, ensuring your production line always runs smoothly with zero downtime.

Conclusion

In the context of the fiercely competitive food industry in both output and quality, maintaining manual film roll loading methods has become obsolete and fraught with risks. Applying industrial manipulators is not just an immediate problem-solving measure, but also a long-term investment strategy to optimise performance (OEE), cut scrap costs, and most importantly, protect the company's invaluable asset – the health of its workers.

Let "Zero Gravity" technology shoulder the weight, free your hands, and break through productivity limits for your factory!

Don't let the loading stage become a bottleneck hindering your growth. Contact Vietmani's team of experts today via Hotline 0936.371.380 - 0931.782.489 or visit our website at vietmani.com for in-depth technical consultation, factory layout surveys, and to receive a completely free design proposal.