AGV Transport System for the FMCG Industry

At a fast-moving consumer goods manufacturing plant, carton supply to case erectors and sealers was previously handled manually. The plant had to assign workers to continuously feed cartons into the machines—an repetitive, labor-intensive task prone to human error.

To overcome these limitations, the factory partnered with ETEK to deploy an AGV-based automated carton feeding solution, aiming for full automation of material supply to ensure continuous, accurate, and safe production line operation.

Project Challenges & Requirements

The project posed significant technical challenges and strict requirements for the ETEK team. First, the system had to operate reliably in a real production environment with limited maneuvering space, multiple machines running simultaneously, and complex transport routes.

ETEK was required to fully synchronize three core components: AGVs, trolleys, and existing case erector machines. Carton feeding had to be precise in both timing and positioning, without disrupting the production line.

Additionally, since the customer’s case erectors had been operating stably for many years, the solution had to remain compatible without altering the main machine structure, while still meeting automation goals. Safety, ease of operation, cost optimization, and clear operational benefits were all mandatory.

ETEK’s Solution

Following on-site assessment, ETEK designed and implemented an external automated carton feeding system based on AGVs, trolleys, and minor enhancements to the existing case erectors.

Operating Principle

One AGV can supply cartons to up to six case erectors, ensuring continuous production through the following cycle:

• When a case erector is about to run out of cartons, the system automatically sends a signal displayed on the HMI.
• Operators load cartons onto the trolley and confirm completion on the system.
• The AGV automatically travels to collect the loaded trolley and transports it to the designated case erector.
• An automatic mechanism on the trolley pushes cartons into the case erector.
• After delivery, the AGV returns the empty trolley to the waiting area and automatically heads to the charging station when required

Equipment Used

AGV Transport Vehicle

ETEK proposed an underride-type AGV equipped with an automatic hook lifting/lowering mechanism to precisely engage and release trolleys. The compact design allows bidirectional movement and flexible operation in confined factory spaces.

With a payload capacity of up to 800 kg, the AGV can move forward, backward, and rotate 90°, reaching a maximum speed of 35 m/min, meeting continuous transport demands. It is equipped with laser safety scanners and anti-collision sensors, automatically stopping when obstacles are detected to ensure safe and stable operation.

Trolley

The trolley features a height of 400–650 mm and width of 565–850 mm, integrated with an auto-centering mechanism and spring holders to keep cartons perfectly aligned for feeding into the case erector. Each trolley can carry up to 100 cartons per cycle, supporting uninterrupted machine operation.

Achieved Results

After completion, the AGV-based automated carton feeding system delivered clear benefits:

• Full automation of the carton feeding process, minimizing manual handling
• Improved production line continuity with no interruptions due to carton shortages
• Enhanced operational safety and reduced industrial risks
• Significant labor and long-term operating cost savings
• Optimized factory layout, well-suited to real-world production spaces