Kinetra AutomationKinetraAutomation
Request a line assessment

Home / Applications / Fresh dairy

Demonstration project · fictional site

Two yoghurt lines. One cell.

A worked example of how a fresh-dairy site with two hand-palletised cup lines could be assessed and laid out. The site, the figures and the outcome are fictional; no results are claimed.

Operators in hairnets working at stainless steel food processing equipment

Situation

Before

Lines
2 cup packers
Rate per line
6–9 trays/min
Tray weight
7.2 kg
Patterns
11
Zone
Chilled, 4 °C
Palletising
Manual, 2 people/shift

Trigger

Why now

The second packer is being upgraded to a faster model, and night shifts at the end of the line are hard to fill. Lifting 7 kg trays at chest height is an ergonomics concern raised internally.

Constraint

What made it hard

Only 26 m² free between the packers and the dispatch door; pallet exits must face the forklift aisle; 11 retailer patterns with frequent short runs.

Approach

From assessment to layout

  1. 01

    Measure the real peak

    Combined peak 18 trays/min after the upgrade, not the 15 on the line sheet.

  2. 02

    Select and check the cell

    KP-40 Duo at 75% utilisation; KP-120 rejected for footprint (42 m²).

  3. 03

    Pattern library

    All 11 patterns rebuilt on the HMI and tested with real trays at FAT.

  4. 04

    Install in a planned stop

    Guarding and infeeds pre-assembled; switch-over planned for a weekend stop.

Top-view layout of the KP-40 Duo: 5.2 by 4.6 metres, 2 infeed lines, 2 pallet stations IN 1IN 2Pallet 1Pallet 2 5.2 m 4.6 m KP-40 Duo · Top View
Proposed layout, 23.9 m² of 26 m²Demonstration drawing
Assumptions used in this demonstration
  • Fictional site and figures, created to show how an assessment is reasoned. Not a client reference.
  • Utilisation = 18 trays/min ÷ 24 rated cases/min. No change in OEE, staffing or cost is claimed.
  • Real outcomes depend on the line, the product and how the site operates.
Assess a similar line KP-40 Duo specs