A leading UK flour mill has strengthened its automation strategy with the installation of a new high-speed robotic palletising and conveyor solution from Endoline Robotics, replacing an older system that could no longer meet the business’s growing demands for flexibility and throughput.
Capable of handling up to 14 bundles of flour per minute across two production lines, the equivalent of between 56 and 168 individual bags of flour every minute, the new system is already playing a key role in supporting increased production volumes and future growth.
Designed to work alongside an existing Endoline palletiser dedicated to one of the site’s two production lines, the upgrade forms part of a broader automation strategy at the facility. The mill operates two filling lines producing both individual 1–2kg bags and larger 18kg shrink-wrapped bundles. The original system, installed five years ago, manages the individual bags from Line 1. This left Line 2’s individual bags, together with the bundles from both lines, requiring a more flexible palletising solution.
Engineered to accommodate both product formats, the system also incorporates the automatic handling and placement of wax paper interlayer sheets. Bundles are conveyed from both lines at speeds of up to 14 per minute per line, equating to a combined throughput of up to 28 bundles per minute. In addition, individual 1–2kg bags from Line 2 are presented at rates of up to 70 bags per minute.
Driving flexibility to support business growth
The replacement project was driven by the need to overcome limitations within the previous palletising operation, which lacked the flexibility to efficiently handle varying bundle sizes and evolving product formats. As the mill expanded its product range and customer requirements for bundle sizes became more diverse, a more adaptable solution was required to support continued growth.
Combining advanced palletising technology with a fully engineered conveyor network, the system enables both bundled flour products and individual packs to flow seamlessly from packing through to pallet build. By automating what were previously labour-intensive and physically demanding tasks, the flour mill has improved operational efficiency, consistency and working conditions across the site.
Integrated palletising and conveyor system
At the heart of the system is a palletising solution capable of managing product streams from the two filling lines. Bundles and individual packs are transferred via a series of accumulation and transfer conveyors, designed to buffer product flow and maintain a continuous feed into the palletising area without disrupting upstream packing operations.
Operating across the two bundling lines, the palletising system can handle up to 14 bundles per minute per line, delivering high-volume throughput while maintaining precise pallet builds and load stability ready for downstream handling and distribution.
While the palletiser can manage the simultaneous pick-up of bundled products from both lines, it requires a straightforward re-tooling process when switching to palletising individual packs of flour, which are fed down the middle conveyor. This quick-change capability allows the mill to move efficiently between product formats in line with production schedules and changing customer requirements.
To minimise downtime during product changeovers, the tooling transition is carried out automatically via the system HMI. The robot docks its current end-of-arm tool, releases it and automatically connects to the alternative tool, ensuring rapid and controlled transitions between bundle and individual pack handling.
Replacing legacy systems with adaptable automation
“Our customer needed a solution that could replace their existing palletising system with something far more adaptable and capable of supporting long-term growth,” comments Suraj Patel, UK Sales Manager, Endoline Robotics. “By integrating high-speed palletising with a tailored conveyor layout, we’ve delivered a flexible operation that can handle different product formats, varying bundle sizes and increasing volumes.”
While enabling the site to move away from manual-intensive tasks, flexibility has been a central design principle throughout the installation. The modular conveyor layout allows for future expansion and capacity increases, while the palletising system can be easily adapted to accommodate new pack sizes, bundle formats and pallet configurations as the business continues to evolve.
“Modern food manufacturers need automation that delivers both performance and adaptability,” Suraj adds. “This project shows how replacing legacy systems with flexible technology can improve efficiency today while providing the capacity to grow tomorrow.”
Building on a long-term partnership
Although the latest installation represents a major upgrade, it builds on an established partnership between the flour milling business and Endoline. In 2020, Endoline delivered a robotic palletising system at the company’s northern England mill to support a sharp increase in retail demand during the pandemic, enabling production of more than 167,000 bags of flour per week and improving pallet quality and operational continuity.
That earlier project helped shape the company’s wider automation strategy and demonstrated the long-term benefits of palletising technology within the milling environment. With more than 200 years of milling heritage, the business continues to invest in modern manufacturing solutions to remain competitive in a rapidly changing food production landscape.
The palletising and conveyor upgrade reflects this industry trend, providing the flour mill with a future-proof solution that supports current operations while enabling continued growth.
