Case Study: Rexam achieves 7.1 cpm and cuts labor with Bastian Solutions' robotic palletizing carousel

Rexam - Customer Case Study

Rexam, a global leader in rigid plastic packaging, needed to centralize palletizing of finished goods (plastic bottle caps), automatically fill and palletize smaller cartons and large totes, implement automatic labeling and inventory tracking, reduce “Mix Ware,” and meet a throughput goal of 7.1 cartons per minute while cutting labor (24 operators over 4 shifts). Bastian Solutions was engaged to deliver an integrated automation solution using a Bastian robotic palletizing cell (Fanuc R2000 6‑axis robot with two horizontal carousels), Savant AGVs, Exacta warehouse control/Event Director, ID Technologies print-and-apply, 3D Datalogic scanners and supporting conveyor and case equipment.

Bastian Solutions implemented the industry’s first robotic palletizing carousel AS/RS using a standard robot and carousels, converted Savant AGVs into mid-level vehicles with four independent intelligent conveyor decks, and integrated labeling and inventory tracking via Exacta and ID Technologies. The solution met the target rate of 7.1 cpm, reduced the number of operators required per shift, and improved automated handling and traceability, delivering measurable throughput and labor savings for Rexam.

Rexam