Equipment:
– Ilersac W High Speed Bagger
– CPH Bag Fold & Seal Closer
– CCTV monitoring system
– Integration into existing process
Client Quote
Wesley Kessack – Project Manger Nestle “The high-speed bagging plant is operating well. It was a complex and well-run project with a very satisfactory result”
Equipment:
Quarry Bagging Systems in Victoria faced significant challenges with their manual bagging and palletizing process, struggling with labor shortages and the physical strain on workers. To address these issues, we designed and implemented a automated solution featuring a B10 Belt Packer, H10 Industrial Sewing System, and FUJI Robotic Palletizer.
This system has increased production efficiency and process reliability while significantly reducing manual handling risks.
The key outcomes delivered include:
✅ Reliable & scalable production for long-term operational growth
✅ Improved workplace safety by minimizing repetitive motion injuries and reducing reliance on manual labor
✅ Maximum reliability & low lifetime costs with robust equipment and superior backup service
This project has transformed their operations, creating a safer and more efficient workplace while ensuring sustainable productivity.
Equipment:
Advanced Feeds has taken a leap forward with a state-of-the-art automation solution provided by Aurora Process Solutions. Previously relying on manual bagging processes, which placed considerable strain on workers handling 40 tons daily, the company sought a more efficient, sustainable approach.
Drawing from past positive experiences with Aurora’s robotics, Advanced Feeds collaborated with Aurora to implement a tailored robotic bagging and palletizing system. The solution supports multiple bag sizes and pallet configurations, ensuring year-round efficiency and flexibility.
The project was delivered on time, within budget, and seamlessly managed. Advanced Feeds praised Aurora for understanding the complexity of their operations and providing a streamlined solution.
The results have been transformative. With manual operations, four staff bagged 4-5 tons per hour. Now, with just two operators, the facility processes 10-12 tons per hour. “It’s a game changer,” the team noted, highlighting improvements in efficiency, reliability, and cost-effectiveness.
This project exemplifies Aurora’s commitment to empowering clients through innovative automation, ensuring sustainable growth and operational excellence.
“It’s a game changer for us”
Equipment:
Azwood, a leader in bio-fuel pellet production for industrial and domestic markets, faced challenges with their manual bag-stacking process. The repetitive, heavy lifting required posed a health and safety risk and made it difficult to find staff willing to perform the task. This labor shortage led to production inconsistencies that impacted their supply chain.
To address these challenges, Aurora installed a Fuji Robotic Palletizer, transforming Azwood’s operation. The automation reduced the labor requirement from three workers to two, and more than doubled their production efficiency. The versatile EC-102 robot handles various bag sizes, efficiently stacking them onto pallets and streamlining the process for transportation. The Fuji Palletizer has truly been a game changer for Azwood, ensuring a safer workplace and greater production consistency.
‘One of our lead drivers was the labor shortage nationally, around the country, we can’t find level entry staff wanting to come in, it is hard back breaking work, and with the robot in play now it’s going to save an injury for a starter’
‘Operators are loving it, it’s all automated now, we have one bagger, fires the bag through the automated sewer and straight to the robot, so that’s way quicker. We freed up two full-time equivalents in that role’
‘The team, the after sales service is great, it’s not just one person in your organization, it’s a whole lot of people there doing a great job’
A first for the industry!
Process Processing faced a significant challenge. As a growing business with two large processing sites in the Methven region of New Zealand, about 10 minutes apart, both facilities handle thousands of bags of high-quality seed each season. All these bags need to be stacked onto pallets for shipping. However, finding seasonal staff willing to take on the physically demanding task of pallet stacking was a constant struggle. This left owners Mark and Deb stepping in before and after work to fill the gap.
Aurora’s engineers partnered with Mark to develop a unique solution: the industry’s first fully mobile, transportable palletizer and wrapper system. Now, they can simply wheel the palletizer into place, where it efficiently stacks and wraps the bags, ready for transport. When it’s time to move to the other site, they just hook the system up to a ute and tow it down the road. Setup takes only minutes, and the palletizer is back to work, freeing up Mark and his team to focus on other areas of the business. Problem solved!
“project management & communication was very good, we know what was happening and when it was happening “
“the operators are fining it very easy to use and enjoyable”
“its increased our productivity no end!”
Equipment:
Hinds Seed Cleaning, a family-owned business based in Hinds, New Zealand, specializes in seed cleaning and processing, serving a wide range of industry needs. Caring for their staff is a top priority for Brian and his family, so it made perfect sense to replace their manual pallet stacking with an automatic palletizer. This upgrade allows their valued team members to focus on more enjoyable, value-adding tasks while eliminating the challenge of finding seasonal manual labor. The installation of the net-weigh packing system has also improved packing accuracy, reducing the cost of product giveaway per bag. One of the biggest wins for Hinds Seed Cleaning has been the ability to operate the rest of the plant at a higher rate, now that the end-of-line palletizing bottleneck has been removed. This improvement enables them to pack on demand, providing their clients with greater flexibility up to the last minute.
“Aurora have been very good to deal with, exceptional “
Equipment:
Hart Bros Seeds has been supplying high-quality seed to both domestic and international markets for over 60 years. Located in the Riverina, NSW, Australia, they’ve grown steadily, building a strong reputation for excellence. Aurora has had the pleasure of working with Hart Bros for several years, supporting their growth and helping to enhance their productivity and free their valued staff from backbreaking tasks.
This particular project presented some interesting engineering challenges due to the layout of their existing plant and wide variation of bag shape. However, the versatility of the FUJI Robotic Palletizer Skid system allowed us to integrate the new palletizing system seamlessly and stack Hart’s full range of products tidily. Now, the robot quietly and efficiently stacks bags on pallets around the clock, requiring minimal intervention. All five plant staff can operate the system with ease, though it hardly needs much attention!
“The new robotic palletizer is amazing!… since installing the palletizer, our output is greater the previous seasons… it’s a great investment for your company’
‘Aurora, they know the grain industry, they are good at it and that makes a big difference when they know exactly what they’re doing’
Equipment:
‘Their knowledge and expertise with the equipment is quite outstanding really, and really easy to deal with, during the project and also after the project’
‘Aurora have a very friendly family orientated business and very easy to deal with.’
Resene Construction Systems, a division of the Resene Group, is a leading supplier to the construction market. They identified the need to enhance their manufacturing plant’s efficiency by reducing manual labor and increasing production output.
Aurora integrated a full end of line automation system, encompassing an automatic valve bagger equipped with ultrasonic sealing technology. This seamlessly connects to a state-of-the-art robotic palletizing and pallet wrapping system.
Key Benefits:
Increased Production Capacity:
The automated packaging line significantly elevated Resene’s production capacity. This has enabled the company to meet increasing demand while maintaining high-quality standards and not having to increase personnel.
Elimination of Repetitive Manual Labor:
The implementation of automation technology eliminated hazardous and repetitive manual tasks. This resulted in a safer and healthier work environment for Resene’s operators.
Reliable Production Process:
The automated system ensures consistent and reliable production runs. This newfound predictability has facilitated accurate forecasting and planning for Resene Construction Systems.
Optimized Pallet Stacking:
The valve bags are now stacked perfectly on the pallet, enhancing brand exposure and ensuring a weather tight and visually appealing presentation of products in storage and transit.
Improved Operator Conditions:
Operators no longer need to work in dangerous, dusty conditions. The automation solution has created a more comfortable and secure working environment, positively impacting job satisfaction and employee morale.
Outcomes: The successful implementation of the automated packaging line has significantly enhanced Resene Construction Systems’ manufacturing operations. It has not only boosted production efficiency and capacity but also elevated the overall quality of work life for its operators.
This project serves as a testament to Resene Construction Systems’ commitment to innovation and operational excellence within the construction industry. The collaboration with Aurora has yielded a transformative solution that sets a new industry standard for efficiency, safety, and product quality.
‘It’s a great robot and its obvious they know their stuff, this gave us confidence’
The issue Dulux faced with the previous robot was that they required more speed. Dulux needed to boost their throughput and the existing technology was a constraint.
Aurora worked with Dulux to specify, supply, install a high-speed Fuji unit that integrated with existing control systems and upstream plant. The Fuji unit is highly reliable and never breaks down which is a significant benefit for high-speed process lines. We provide routine maintenance to ensure its running at peak performance and train any new staff.
Seales Winslow, a leading stockfeed manufacturer, recognized the need for a transformative upgrade to their existing manual bagging process. The traditional approach had become increasingly physically demanding and led to production inconsistencies across shifts. Human resource allocation and management was also a challenge.
In collaboration with Aurora and partners TMI, Seales Winslow embarked on a project to implement a state-of-the-art high-speed bagging system. This innovative solution not only empowered Seales to meet market demands but also alleviated labor-intensive tasks, eliminated health and safety concerns, and ensured a reliable and predictable output. This project stands as a significant victory for Seales Winslow, marking a milestone in their operational efficiency and competitiveness.
“It’s definitely increased our output, in terms of what we can bag in a day.”
“Super intuitive, super easy to use, the training has been very easy.”
“The Wealth and knowledge in Aurora, there isn’t any time we can’t call Aurora up and get an answer straight away.”
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