Design of a Robotic Pick & Place Mechanism for Replacing the Manual Handling of Milk Powder Tin Cans

Abstract

Automation has become an important part of modern industries as it helps improve efficiency and maintain consistency in repetitive tasks. Pick-and-place operations are widely used in packaging and material handling, where objects need to be moved from one place to another accurately and repeatedly. When these tasks are performed manually, they often lead to variations in cycle time, worker fatigue, and a higher chance of errors. In this project, an automated pick-and-place system is designed to handle cylindrical containers in an efficient way. The system uses a hybrid Cartesian robotic mechanism, combining linear motion for positioning and rotary motion for orientation. A vacuum-based gripper is used to lift and hold the containers securely. Proper calculations are carried out to determine the required vacuum pressure based on the weight of the containers and the suction area, ensuring safe and reliable operation. The developed system improves placement accuracy, reduces the need for manual effort, and provides consistent performance. In addition, cost analysis shows that although the initial investment is required, automation offers long-term economic benefits by reducing labor costs. Overall, the system presents a practical and reliable solution for automating repetitive packaging operations.

Introduction

The text describes the design and justification of an automated pick-and-place robotic system for handling cylindrical containers in packaging operations, aimed at replacing inefficient manual processes.

In the existing manual system, workers pick containers from a conveyor and place them into boxes. This process suffers from inconsistent cycle time, placement errors, worker fatigue, and limited scalability, with each box taking around 23–25 seconds to pack. These issues reduce productivity and increase operational costs.

To overcome these problems, the proposed system introduces an automated robotic solution that uses a Cartesian motion structure with linear actuators and an added rotary mechanism, along with a vacuum-based gripper for safe handling of containers. The system is controlled through a programmable controller that coordinates motion, sensors, and vacuum operation to ensure precise and repeatable pick-and-place cycles.

The main objectives are to standardize cycle time, improve accuracy, reduce human effort, enhance efficiency, and lower long-term costs. The robot performs a defined sequence: detect objects, pick them using vacuum suction, optionally rotate them, place them in boxes, and repeat the cycle.

A Cartesian robot with rotary motion is selected because it provides high accuracy for linear movements in grid-based packaging layouts, while the added rotary unit handles orientation tasks without the complexity of fully articulated robots.

Conclusion

This project presents the design of an automated pick-and-place system for handling cylindrical containers using a hybrid Cartesian robotic mechanism integrated with a vacuum-based gripping system. The proposed system aims to replace manual handling operations with an efficient automated solution capable of performing repetitive tasks with higher accuracy and consistency. The study analyzed the limitations of manual operations, including inconsistent cycle time, worker fatigue, and higher probability of human errors. Based on these challenges, an automated solution was proposed that integrates linear motion mechanisms, rotary orientation control, vacuum gripping technology, and an electronic control system. Technical calculations were performed to determine the required vacuum pressure for safely lifting the containers. The design ensures stable gripping and reliable operation while maintaining safety factors for real operating conditions. The selection of a hybrid Cartesian configuration provides a balance between mechanical simplicity, structural rigidity, and precise positioning capability. Economic analysis shows that the proposed system is financially feasible, as the automation cost can be recovered within a short period when compared with recurring manual labor expenses. Additionally, the automated system improves productivity, reduces operational variability, and ensures consistent performance. Overall, the proposed design demonstrates a practical and efficient approach for automating repetitive pick-and-place operations, offering improved reliability, accuracy, and long-term cost benefits.

References

[1] Groover, M. P., Automation, Production Systems, and Computer-Integrated Manufacturing, 4th ed., Pearson Education, 2015. [2] Siciliano, B., Sciavicco, L., Villani, L., and Oriolo, G., Robotics: Modelling, Planning and Control, Springer, 2009. [3] Bolton, W., Mechatronics: Electronic Control Systems in Mechanical and Electrical Engineering, 6th ed., Pearson, 2015. [4] Niku, S. B., Introduction to Robotics: Analysis, Control, Applications, 2nd ed., Wiley, 2010. [5] Craig, J. J., Introduction to Robotics: Mechanics and Control, 3rd ed., Pearson, 2004. [6] SMC Corporation, Vacuum Equipment and System Design Guide, SMC Pneumatics Manual. [7] FESTO Didactic, Pneumatics Basic Level Training Manual, Festo, Germany.

Copyright

Copyright © 2026 Rohit Singh, Om Gohel, Purvi D. Chauhan. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.