Case Study: Crown Cork & Seal achieves automated scrap-aluminum palletizing and reduced labor/injuries with Bastian Solutions' robotic palletizing system

Crown Cork & Seal - Customer Case Study

Crown Cork & Seal in Mankato, Minnesota needed a way to palletize variable‑length bright scrap aluminum bales (4"–41", baseline 42") that produced unique pallet patterns each load, reduce operational costs and ergonomic risk, and fit inside an existing baler scrap room. Crown Cork & Seal engaged Bastian Solutions to deliver a Robotic Scrap Metal Palletizing System using a FANUC R-2000iB 165kg robot, Bastian Robotics servo‑driven EOAT, conveyors and integrated PLC/HMI to meet these constrained requirements.

Bastian Solutions implemented a full‑layer robotic palletizing cell with servo EOAT, drag‑chain conveyors and integrated controls that met required throughput while providing 50% over‑speed capacity for future expansion. The system removed operator handling during normal production, added a robotic‑cell bypass for maintenance/downtime, delivered ROI through reduced manpower and fewer work‑related injuries, and resulted in a follow‑up order for the Cheraw, SC facility plus a letter of recommendation.

Crown Cork & Seal