SOMIC automates magazine loading for carton packaging machines with SOMIC CoboLoad and Yaskawa

Food, cosmetics, pet food and many other consumer goods to a retail value of millions are well protected by sturdy shipping containers or shelf-ready packaging. With many renowned brand manufacturers, the boxes are filled by the machines of SOMIC Verpackungsmaschinen GmbH & Co. KG.

The company, based in Amerang, Bavaria, has specialised in the field of production automation for over 50 years. As the market leader in secondary and final packaging, SOMIC has been setting standards for many years. Its portfolio includes customized solutions for single- and multi-part cardboard packaging in a wide variety of sizes and formats.

What all systems have in common is the combination of the highest precision and speed. In addition, they are characterized by very high power density in the smallest space, maximum energy and resource efficiency, as well as durability and gentle handling of the prepackaged products.

Picture: The SOMIC CoboLoad ensures automatic carton supply to the machine – without the need for human intervention.

SOMIC CoboLoad automates loading of the carton magazine

From the very beginning, constant optimization and further development have been a central pillar of SOMIC's corporate culture. In a recently completed project, the in-house R&D department sought a solution for feeding the cardboard blanks into the machine. Manually executed, this work stage often involves physical stress and interruptions that cost valuable production time. A method of automated loading of the carton magazine was thus required in order to relieve the staff of these monotonous, strenuous activities and at the same time increase process safety and production performance.

Development of the project was started under the direction of Brigitte Stockenreiter. SOMIC was able to present the market-ready result at Interpack 2026. The SOMIC CoboLoad tirelessly ensures the continuous supply of cardboard to the machine across an entire pallet – without the need for human intervention.

This culminates in concrete advantages such as higher line availability, uniform carton feeding, improved ergonomics, lower personnel costs and less need for manual work. The result is an efficient flow of material throughout the packaging line – even during the entire night shift. At the same time, automation allows operating personnel to focus on monitoring and other value-added tasks.

Picture: The heart of Yaskawa’s solution is a HC20DTP cobot.

Combination of robotics and intelligent sensor technology

The system combines modern robotics with intelligent sensor technology. More specifically, it combines intelligent image processing and sensor-assisted gripping technology. This means that even differently aligned cardboard stacks can be reliably handled.

The core element of the SOMIC CoboLoad is a cobot, a collaborating robot that can load a carton magazine. The robots are equipped with a special gripper from Somic. This is generally available in two different versions: either the standard inner gripper or an outer gripper for individual carton shapes. Normally, several carton formats run on one machine. A quick-change tool system ensures the necessary high flexibility.

By using 3D vision technology, the robot automatically detects the position of the stacks. Controlled by sensors, it then precisely grips them and deposits them safely and reliably in the magazine. Stack inclinations or offsets are automatically compensated, and intermediate layers are removed as needed using vacuum suction cups. If the orientation of the blanks must be changed before settling in the magazine, this can be done via an optional turning station.

Picture: The HC20DTP offers a wide operating range and thus reaches all points of a standard Euro pallet.

HRC-capable industrial robot

Since the robot operates in close proximity to the operating personnel, it should be designed for safe human-robot collaboration (HRC). Yaskawa's HRC-capable HC20DTP robot with PL-d certified safety control (FSU) and completely internal cable routing meets this requirement and thus offers the highest level of safety for operators and the immediate environment. There are other reasons why SOMIC chose this model specifically, as Project Manager Brigitte Stockenreiter explains: “The charming thing about it is: the HC20DTP is a fully-fledged industrial robot with correspondingly high power and speed, which can also be operated as a cobot. This means that a protective fence or other safety devices are not required during secured operation, so that the robot can be easily and space-savingly integrated into existing environments. With appropriate safety measures – such as light barriers or contact tread mats – faster applications are also possible.”

Another important argument for the HC20DTP is its wide range: measured from the centre of rotation of the base to the outermost operating point, this is 1,900 mm. The robotic arm thus reaches every point on a standard Euro pallet. It can be loaded with up to 20 kg (including tools). The maximum working speed is up to 2 m/s, depending on the load. Nevertheless, the robot works with high precision: repeatability is 0.05 mm. And last but not least, all cobots of the HC series are designed in dust and waterproof IP67 protection class.

Picture: Project Manager Brigitte Stockenreiter: “We know we are excellently positioned with this robot.”

Full integration into the PLC

The robot was also intended to meet special control requirements. Project Manager Stockenreiter sums it up: “Our SOMIC standard control system was set from the outset during the development of the CoboLoad. The robot world has its own language, but we wanted full integration into our control environment. The robot should definitely be able to be controlled or programmed via these.”

Yaskawa has met this requirement with the proven MotoLogix software interface. This allows the manufacturer’s robots to be quickly and easily programmed and controlled via the PLC in the common IEC-61131 environment. The range of supported platforms includes all common standards. Integration into the PLC preserves all the genuine advantages of robot control. Thus, the robot controller calculates the motion kinematics and ensures high motion quality. This applies regardless of whether the SOMIC CoboLoad is operated as a stand-alone solution or integrated into a larger line via OPC UA.

In addition, with MotoLogix, PLC knowledge is sufficient to control the robot. “We've also integrated our HMI,” Stockenreiter adds. “So the customer can control the robot 1:1 in the familiar environment and with the same look and feel.”

Picture: With MotoLogix, the robot can be operated directly via the familiar control environment.

Outlook

The development work to automate magazine loading in carton packaging machines has proved worthwhile. The new SOMIC CoboLoad was very well received by trade fair visitors at Interpack 2026. Initial client projects are already in preparation. This also confirmed Project Manager Stockenreiter and the others responsible at Somic in their decision in favour of Yaskawa’s HC20DTP. “It’s perfect for magazine loading; from a robotics point of view we are not missing anything. We know we are excellently positioned with this robot.”

Pictures: © SOMIC Verpackungsmaschinen GmbH & Co. KG

Author: Florian Kohut, Key Account Manager, Yaskawa Europe GmbH