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Highly Automated Packaging and Palletizing for the Thermomix TM7 at
VORWERK

Packaging and palletizing as a central element of the new distribution center

With the construction of a highly automated distribution center at its Schwelm site, VORWERK has laid the foundation for a logistics operation that is both scalable in the long term and competitive on a global level. A key component of this concept is the automated packaging and palletizing of the Thermomix TM7. Unchained Robotics, together with system partner HEBER, implemented a high-performance packaging and palletizing solution that was designed as an integral part of the warehouse and production layout from the very beginning.
The system handles fully automated processing of individual cartons and set cartons, as well as reliable palletizing for outbound logistics. The objective was to establish a stable, reproducible, and continuous process capable of handling high volumes over the long term while consistently meeting the high quality standards associated with the VORWERK brand.


Customer Profile VORWERK

VORWERK is a globally operating manufacturer of high-quality household appliances headquartered in Schwelm, Germany. The company is internationally renowned, particularly for the Thermomix, and stands for precision, innovation, and long-term product reliability.
To meet growing global demand, VORWERK continuously invests in modern production and logistics concepts. Automation plays a central role in ensuring efficiency, quality, and long-term planning reliability across all stages of the value chain.


Customer

VORWERK, Schwelm, Germany

Application

Handling and palletizing of cartons

Software

LUNA Automation Operating System

Hardware

6x MalocherBot M (Pick-and-Place), 3x MalocherBot XL (Palettierung), KUKA KR20 und KR140; PIAB-KENOS-Greifer und Spezialgreifer

System Integration

Unchained Robotics

Commissioning

2025

Result

High process stability and consistent cycle times in packaging the Thermomix

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Projektverantwortlicher Logistik

VORWERK

Challenge Preparing the new packaging site for global competitiveness

As part of the construction of the new distribution center, VORWERK set out to implement a highly automated packaging and palletizing line that would meet the requirements of a globally operating premium manufacturer. The aim was to significantly reduce manual dependencies while enabling stable and predictable workforce planning.
Additional challenges arose from the product itself: packaging the Thermomix TM7 must be fast, process-safe, and consistently high in quality. High throughput rates, reproducible pallet patterns, and reliable multi-shift capability were therefore essential requirements. Automation was not an optional add-on, but a fundamental element of the overall concept for the new facility.


Solution High-performance packaging and palletizing solution with MalocherBot and KUKA industrial robots

To meet these requirements, a comprehensive packaging and palletizing solution was implemented, consisting of multiple MalocherBot cells with a total of six KUKA industrial robots specifically designed for use in large-scale logistics environments.
Three MalocherBot M cells perform pick-and-place tasks in the packaging process, while three MalocherBot XL cells are responsible for palletizing the finished Thermomix cartons. Control is handled via the LUNA Automation Operating System, ensuring stable processes and intuitive operation.

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Quote Image

Projektverantwortlicher Logistik

VORWERK

System Configuration and Specifications

Cells

6× MalocherBot M (Pick & Place), 3× MalocherBot XL (Palletizing)

Robots

KUKA KR20, KUKA KR140

Grippers

PIAB KENOS (Singlepick), PIAB Custom and Multipick Grippers

Software

LUNA Automation Operating System (PLC)

Products

Einzelkarton TM7, Setkartons TM7 (4 Stück), Paletten und Zwischenlagen

Maximale Traglast

20 kg / 140 kg

Palettenmuster

8 Lagen à 4 Kartons

Zykluszeiten

25 s / 12,5 s

Grundfläche

ca. 26 m² / ca. 50 m²

Sicherheit

Schutzzaun mit Muting-Lichtgittern



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Business Results

With the commissioning of the new distribution center, VORWERK achieved a very high level of automation in packaging and palletizing from the very first day of operation. The system delivers stable, reproducible packaging quality and reliable throughput in multi-shift operation.

Cartons, plastic containers, bags and more. The PIAB vacuum system and LUNA pattern tools support a wide variety of packaging. We validate edge formats during project planning.

Operators can add/change carton types and pallet patterns directly in LUNA. No external programming required. This reduces changeover times and keeps throughput stable during SKU changes.

We use your labor rate, cases/minute, pallets/hour, shifts and downtime to estimate savings and payback times in months. Give us your numbers to get a customized model.

Dual-pick increases cartons/minute without expanding footprint. We map your target cycle time to pallets/hour in the ROI estimate.

Yes. We integrate safety and compliance according to EU standards (CE) with proven components (KUKA, PIAB). Details on hygiene and safety guards are determined during layout review.

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