La versione del browser Internet Explorer in uso non è aggiornata. Per una rappresentazione ottimale vi consigliamo un aggiornamento del browser
1200 Cans per Minute: Clevertech and KUKA Deliver High-Speed Robotic Automation for the Pet Food Industry
To meet growing demand without replacing existing lines, Clevertech developed a high-speed robotic solution for aluminum can handling in the pet food sector. Implemented in Poland for a major pet food manufacturer, the system demonstrates the scalability of the solution across international markets. With KUKA robots, the system achieves 1200 cpm and over 98% efficiency in the sterilization area.
Pet Food Industry Innovation: Clevertech and KUKA Automate Can Handling for Growing Market Needs
Clevertech has long been a strategic player in the automation of end-of-line systems across multiple industries.
Among them, the pet food sector has emerged as one of the company’s most dynamic and innovation-driven markets—second only to food & beverage in terms of volume.
In fact, over 80% of Clevertech’s pet food systems are powered by KUKA robots, a testament to a long-standing and trusted collaboration.
As explored in our previous case study, Clevertech Hurricane: 5 KUKA Robots optimize Pet Food Handling in 74 sqm, the industry is undergoing rapid transformation.
“The “humanization” of pet food—with products resembling yogurts, smoothies, and vegetable blends—has introduced new challenges in product handling.
These formats require multiple manipulation steps, more delicate treatment, and higher throughput, making robotics not just an option, but a necessity,” says Luca Carollo, Business Developer at Clevertech.
Speed Meets Complexity — The Challenge of Product Geometry
Rising demand doesn’t just mean producing more—it means producing faster, smarter, and with greater control over increasingly complex product formats.
For one global manufacturer, this meant expanding production capacity without replacing existing lines, while ensuring that every can entering the sterilization process was handled with precision and consistency.
Automation for Pet Food Industry
Energy Efficiency, Moisture Management, and Material Durability
Beyond the geometry of the product, the customer also faced challenges in energy efficiency.
In thermal sterilization, every empty space in a layer of cans represents wasted energy.
Ensuring that each layer is complete and stable is essential—not only for product quality, but for operational sustainability.
Post-sterilization, the challenge shifted: the cans, now wet and thermally stressed, had to be unloaded without introducing moisture into the system.
From Concept to Execution: How Clevertech and KUKA Delivered a Scalable Robotic Can Handling System
The pet food market is shifting—toward smaller formats, faster cycles, and more frequent product changes.
“We’re seeing in pet food what happened in beverage years ago: a shrinking of formats,” explains Luca Carollo. “And now, with this technology, we can manage those volumes—1200 cans per minute today, and even higher speeds in future systems.”
To meet these demands, Clevertech developed a robotic solution using two KUKA models per station:
The KUKA KR120 R3200 PA, a high-speed palletizing robot, handles the interlayer sheets with precision.
The KUKA KR180 R3200 PA, paired with Clevertech’s patented Hybrid Sweep-off head, manages the aluminum cans.
This gripping system combines vacuum and mechanical push to gently lift and transfer full layers of cans—just a few millimeters off the surface—without disrupting alignment.
“It’s not just about picking up the cans,” Luca Carollo explains. “It’s about controlling how they behave when pushed together. The Hybrid Sweep-off system, a patented technology designed by Clevertech, lets us lift and move the layer without gaps, which is critical for thermal treatment".
The patent numbers for Hybrid Sweep Off technology are in the EU and USA with the following numbers:
EU: E1.C0019.12.EP.28
USA: E1.C0019.12.US.28
Post-sterilization, the unloading unit uses a mechanical-only approach to avoid moisture interference, while the interlayer sheets are rotated alternately to prevent warping and extend their usable life.
Clevertech and KUKA partnership
Efficiency That Supports Sustainability
Beyond speed and precision, the system delivers measurable sustainability benefits.
By ensuring complete layers, the customer avoids wasting energy during sterilization.
And by preserving the condition of interlayer sheets, they reduce material waste and replacement costs.
“Every empty spot in a layer means wasted energy,” Luca Carollo notes. “And every warped interlayer means replacement costs. This system helps the customer stay efficient and sustainable.”
With over 98% operational efficiency and a scalable design, the solution is not only fast—it’s built for long-term performance and replicability across multiple sites.
Clevertech Pet Food Solution
Scalable Robotics and Future-Ready Automation: A Partnership Built for Growth
The collaboration with KUKA has extended across multiple projects, particularly in the Pet Food industry.
KUKA robots stand out for their wide range of motion, extensive product range, and a combination of robustness and motion precision.
One of the main advantages is their ability to handle extra payloads during specific phases of the work cycle, offering greater flexibility in demanding applications.
Palletizing Solution
Ready for What’s Next: From Pouches to Mobile Palletizing
The flexibility of the system is already being demonstrated in other projects.
A similar robotic setup is now being used for pouch handling in Romania, where the product’s nature prevents accumulation and requires even more delicate manipulation.
“It’s the same logic: KUKA in loading, KUKA in unloading, one robot handling the product, the other managing the flow” Luca Carollo explains.
Looking ahead, Clevertech is also developing mobile palletizing cells—compact, plug-and-play units equipped with KUKA robots and premium components. These systems can be moved between lines as needed, offering a cost-effective and flexible solution for dynamic production environments.
“We’ll be presenting this new solution at Anuga FoodTec and Drinktec in India,” Luca Carollo adds.
“It’s built in India, but with the same high-end components. It’s a smart, scalable option for both emerging and mature markets.”
[Robotics solution for sterilization]
By combining Clevertech’s automation expertise with KUKA’s programming capabilities, we optimized robot cycle times and ensured safe, collision-free operation in shared workspaces
