Introduction
As the old saying goes, it’s no use crying over spilled milk. But when we’re talking about dairy production and not the dinner table, that’s a different conversation.
To stay competitive, companies face the challenge of staying current with technology without disrupting operations or overspending. A skilled integration partner knows when to replace a system entirely and when to strategically upgrade what’s already in place. By retrofitting instead of rebuilding, we can help you bridge that gap.
Rather than invest in new, expensive equipment, our client chose retrofit robotics solutions to optimize what already fits in their space. Our team supported two projects inside the facility, each designed to improve system reliability, extend equipment life and prepare the client’s operations for the future challenges of the food processing industry.
Quick Facts
| Client: | Food Processing |
| Application: | Material Handling |
| Core Solution: | Robotics & Controls |
| Technologies: | Material Handling, Palletizing, Robotics |
| Outcomes: |
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The Challenge
The client, a dairy product processor, sought our team’s support with the palletizing cell for milk. In this cell, two robots receive items from a conveyor belt. When the products arrive, the robots place slip sheets between the layers of boxes and palletize stacks of products on top of each other.
Outdated robotic controls were causing downtime and damaging their dairy products. In the facility’s storage area, which stays just above freezing, robots’ inconsistent grip and handling of materials resulted in cases of milk to drop and spray over the equipment and floors.
Whenever products dropped, operations would have to stop to clean up the mess. Process delays also caused backlogs of pasteurized milk in warm zones, leading to both product and revenue loss.
Retrofit Robotics Solutions for Two Unique Challenges
To solve these issues, Hyperion developed two solutions to retrofit the robotic cells. Each addressed a unique part of the facility but shared the goal of extending equipment life and optimizing for the future. The client needed to upgrade their aging robotic systems without making significant investments. Although their KUKA robots were in good mechanical condition, the controllers used an outdated DeviceNet I/O system with limited performance
This outdated technology can’t match Ethernet’s speed or flexibility, which offers more capabilities to handle future demands. The old system raised reliability concerns, especially with the evolving needs of the food processing industry. The client needed a solution that would be both reliable and competitive.
To make this happen, our engineers worked closely with technology partners and meticulously planned the integrations.
Step 1 – Controls Upgrade & Retrofit for KR240
Our team worked with KUKA to upgrade the controller on the KR240 6-axis robot, which plays a critical role in the warehouse. This robot palletizes boxes filled with gallon-sized containers of products and places slip sheets between layers to help stabilize the load and prevent tipping.
Any downtime or inconsistency in its operation would directly impact product throughput and packaging integrity. Frequent downtime and maintenance needs made the previous controller an efficiency concern. The upgrade allows our client to switch to modern palletizing software that’s easier to maintain and standardized across all robots in the facility.
To ensure the system was compatible with modern technology, our team upgraded the I/O system from DeviceNet to Ethernet. This change allowed the robot’s controller to communicate more efficiently with its components. We also replaced the old cable package with new power and signal lines and installed connectors that meet current industry standards. After connecting everything to the new KRC4 controller, our engineers fine-tuned the system to ensure optimal performance after the installation.
After evaluating the system, KUKA converted the robot’s current programs to run on a new KRC4 controller. During installation, we routed new hardware and worked closely with a KUKA technician to calibrate the system. We also installed a KRC4 controller box, giving the robot a centrally-located control hub for our client’s team to easily find and operate.
Finally, we went through fine-tuning to ensure optimal performance after the installation.
Step 2 – End-of-Arm-Tool Upgrade
The second project focused on replacing a worn-out end-of-arm tool (EOAT) for handling pallets and slip sheets. This robot is responsible for lifting full pallets of boxed products and staging them for the next step in the process. Inconsistent tool performance at this stage could disrupt workflow and compromise product stability.
The original setup used a clamp-style tool with a separate vacuum circuit to grip the outside of cases and lift slip sheets with vacuum cups. As the tool’s performance declined over time, it created reliability issues and limited throughput. Condensation from cold products also softens the cardboard boxes, making it harder for the end tool to grip. The original EOAT uses a swivel joint to comply with the robot and the milk boxes during picking. This joint has become worn out, breaking or freezing often. This causes the robot to lose compliance, resulting in gallons of milk spraying across the cold room.
The system also runs on an outdated I/O network, which makes it harder to connect with modern technology.
Hyperion worked closely with the client and Joulin to modernize this workflow with a more reliable EOAT. The new tool uses the same vacuum foam pad to handle both boxes and slip sheets, simplifying the design and reducing system complexity.
Previously, the end tool used a separate vacuum circuit and dedicated cups for slip sheets. The new version uses compliant foam combined with vacuum across the entire surface, allowing it to easily lift both boxes and slip sheets. With the retrofit solution, the robot can now palletize and place slip sheets without any interruption.
To support the tool’s functionality, we installed a -blower system that creates the vacuum effect and moves air through a reinforced hose connected to the gripper.
Retrofit Robotics System Results
You don’t need to start from scratch to stay competitive with your technology. Through close collaboration with partners from KUKA and Joulin, Hyperion was able to deliver retrofit robotics solutions that extend equipment life, reduce costs and keep production running strong.
Our approach allowed our food processing client to:
Save money on equipment expenses. By upgrading key components instead of replacing entire systems, we helped our client avoid major capital investments and operational disruptions. As technology nears the end of its life cycle, spare parts can become costly and harder to find. Preserving what works and improving what doesn’t, giving our clients the best value.
Extend the life of their equipment. We support our clients through every stage of their system’s lifespan. By replacing outdated controllers, tools, and I/O systems, our team delivers upgrades that provide extra years of value on top of our client’s original investment in technology.
Scale operations with confidence. Innovative robot retrofit strategies make it easier to grow your operations without substantial capital investment. With modern systems and a clear plan for future upgrades, our client has the flexibility to scale efficiently without sacrificing performance.
Save revenue and product through reduced maintenance downtime. In the original process, downtime led to pallets of product spoiling while waiting for equipment repairs. With the implementation of the new controller and EOAT, production runs strong and now preserves revenue and products.
Partner with Hyperion
The right retrofit keeps your systems running smoothly and positions your operations for success. Contact us today to discuss tailored solutions that maximize the value of your existing systems.
