In detergent production line automation projects, the biggest challenge we often encounter is not only productivity, but also operational stability, the ability to handle diverse packaging sizes, and a dusty working environment. Therefore, Intech designs the detergent handling and loading line in a synchronized, flexible, and scalable manner, with the following key components playing crucial roles:

Overview of the project for a detergent manufacturing plant

1. Palletizing Robot System

At the final stage of the production line, palletizing robots are the "heart" of the automated detergent packaging system. This is a labor-intensive area with potential safety risks and difficulty in ensuring uniformity if done manually.

The palletizing robots are responsible for stacking bags, pouches, or containers of detergent onto pallets according to a pre-programmed diagram, ensuring:

• Neat and sturdy pallets
• Easy to wrap with film – transport – and store
• Consistent in appearance and stacking quality

In actual projects, the system can completely replace 3–5 workers per shift, operating continuously 24/7 without a decrease in efficiency.

Robot technical structure:

• Robot arm: Uses a 4-axis or 6-axis robot, selected based on:

+ Detergent powder bag load (5kg – 25kg)

+ Required speed

+ Pallet stacking space

• End Effector: This component is specifically designed by Intech for their detergent products:

+ Anti-slip mechanical clamp for heavy bags

+ Vacuum suction cup for cardboard boxes

+ Dust-resistant material to prevent bag tearing

• Control System:

+ Industrial PLC

+ Intuitive HMI screen

+ Programming for various pallet stacking patterns (by SKU)

• Base and support frame: Precisely machined, ensuring rigidity when the robot operates at high speeds.

• Safety system:

+ Protective barrier

+ Safety sensors

+ Factory-standard Emergency Stop

Intech's solution: Programmed robots automatically stack pallets according to an optimized force distribution pattern, ensuring stable and professional pallets while maintaining high speed and repeatability. This is a key solution to help businesses standardize the final stage of their production line.

2. Roller Conveyor System – Transporting Finished Detergent Powder Products

In detergent powder production lines, roller conveyors are widely used to transport finished products after packaging due to their good load-bearing capacity and durable construction.

The specific structure is as follows:

• Rollers: steel, stainless steel, or engineering plastic, free-rotating or driven

• Conveyor frame: powder-coated steel, stainless steel, or extruded aluminum

• Support legs/adjustable legs: easily adjustable height to suit the factory floor

• Drive system: motor – chain – belt or gear

Roller conveyor position in the module:

• After the packaging machine
•  
• Before the loading robot
•  
• Pallet transfer or lane separation area

Intech solution: The system is calculated to suit the load capacity and roller pitch for flat-bottomed detergent bags/containers, helping to:

• Ensure continuous product flow
• Reduce impact and minimize bag deformation
• Optimize space and operating manpower

3. PVC Belt Conveyors

Alongside roller conveyors, PVC belt conveyors play a role in connecting the various stages in the entire production line.

The PVC conveyor belt structure must ensure:

• PVC conveyor belt: abrasion-resistant, moisture-resistant, smooth or ribbed surface
• Conveyor frame: steel, stainless steel, or aluminum
• Support rollers & drive rollers
• Motor + gearbox
• Belt tensioning system

Application locations for PVC conveyor belts:

• From mixer → packaging
• From packaging → collection area
• Transporting light to medium weight detergent powder bags/pouches

4. Control cabinet & management software

In modern projects, hardware is only half the story. The control system and software are the decisive factors for long-term operational capability.

Key Components:

• PLC + HMI monitoring the entire production line
• Flexible programming for multiple pallet stacking patterns
• Easy modification when product specifications change

Smart connectivity:

• MES/SCADA connection
• Production data collection
• Support for productivity management and operational traceability

The detergent handling and loading line implemented by Intech aims not only to automate individual devices but also to optimize the overall production flow, helping the factory:

• Increase productivity
• Reduce reliance on labor
• Standardize pallet quality
• Ready for the Smart Factory model - the most modern production line.