MP3300iec RBT machine controller optimizes baking process

Fully systematized piadine production

By using a Yaskawa MP3300iec RBT machine controller, the Italian system integrator Bosso Automazioni was able to optimize the performance of a pick-and-place system at a manufacturer of traditional “piadines” or Italian flatbreads. The benefits include lower operating costs, the prevention of downtime and waste, an extended service life for the equipment and thus higher overall profitability.

Described as the “national bread of Ramogna” by Italian poet Giovanni Pascoli, the origin of the piadine dates back to the times of the ancient Romans. Yet even today, the piadine is still well loved by both young and old alike. Over the years, piadine production has spread across the borders of Italy and seen rapid international growth. According to data from the Consortium for the Promotion and Protection of Piadina Romagnola, piadine production increased further still in 2020 as a result of the Covid-19 pandemic, reaching an impressive 22,030 tons. This corresponds to an increase of 23.3% compared to the previous year. However, it would not be possible to satisfy the growing demand in the market without well-functioning production lines.

An underperforming pick-and-place system

It was for this reason that a piadine production plant in the province of Rimini approached system integrator Bosso Automazioni (www.bosso.it). Since 2001, the Rimini-based system integrator has been designing custom machinery and working in partnership with Yaskawa to implement its innovative ideas.

It was this close collaboration that enabled the company to redesign the plant's pick-and-place system, which is used to stack the piadine ready for packaging. The previous system was severely outdated, based on an obsolete concept and included non-industry-standard components (such as cameras).

With two delta robots, each guided by a separate controller with MECHATROLINK-II interface and Sigma-7 servo motors, the production line had never achieved the desired results. Despite adding an extra robot, the plant was still dealing with low efficiency, inadequate product holding fixtures, frequent component failures and overloading of amplifiers. With the increase in production rates required to meet peak demand, these issues were only going to get worse.