ACME Foods: 175% Throughput Increase with Delta Robot Pick & Place

Challenge

ACME Foods operated a manual bakery sortation line running at 80 picks per minute with four operators per shift. Increasing demand required either doubling headcount or automating — in a facility with limited floor space and strict hygiene requirements.

Solution

We deployed a four-robot Delta cell with IP69K washdown configuration:

• 4x Adeeb Delta Robots with NSF-certified stainless arms
• Vision system for product detection on moving conveyor
• EtherCAT Master Professional synchronizing all axes at 1ms cycle time
• Custom vacuum end-effectors for gentle pastry handling

Results

The cell went from commissioning to 24/7 production in 6 weeks. Line throughput increased from 80 PPM to 220 PPM with one supervisor replacing four operators.

Product waste from handling damage dropped from 3.2% to 0.4% — the gentle vacuum grip and precise placement eliminated the crushing and misalignment common in manual operations.

“We needed to triple output without tripling our workforce. The Delta cell paid for itself in 14 months and hasn’t missed a shift since commissioning.” — Operations Director, ACME Foods