Mpac and Lenze develop scalable eight-robot packaging line

“With the digital twin, we were able to validate our solution before the machine was built. That significantly reduced risk for everyone involved.” With this statement, Berto Mathijssen, Technical Director at Mpac, captures the essence of the joint project with Lenze.

Together, Mpac and Lenze developed a scalable multi-robot picking platform. Eight robots, distributed across four independent cells, handle more than 200 different products per cell without impacting overall line throughput. This is made possible by efficient material flow and a highly flexible machine design, while also reducing downtime and significantly simplifying operation. Product and recipe changeovers can be performed quickly and intuitively.

The challenge: A flexible packaging line for a wide product range

Multi-axis robot cell in an automated packaging line on the production floor.

Mpac initially planned a conventional robot-based packaging line. As the project progressed, however, it became clear that this approach would not fully meet the end customer's requirements, particularly the need to handle a large variety of products within a limited footprint. A fundamentally different, scalable approach was required.

The digital twin as a success factor: From simulation to rapid commissioning

To prove feasibility before machine construction began, Mpac and Lenze relied on a digital twin. This enabled process flows and performance requirements to be simulated and validated at an early stage, long before the first component was manufactured. As a result, project risk was significantly reduced for all stakeholders and commissioning efficiency improved dramatically.

Through virtual design, simulation, and validation, commissioning productivity increased from approximately one robot per week to three or four robots per week.

The impact was also reflected in the project timeline. For a machine of this complexity, achieving delivery within 18 months from initial inquiry is remarkably fast. This was made possible by extensive virtual preparation, which significantly streamlined implementation. Robotics proved to be the key to turning a complex mechanical challenge into a manageable, scalable solution.

Digital twin of a robot cell transitioning into the real packaging system.

Lenze and Mpac: Partners in packaging automation

Mpac and Lenze have worked together in packaging automation for more than 25 years. This close partnership, combined with the early virtual validation of the solution, was a critical factor in successfully delivering this ambitious project within a challenging timeframe.

Two colleagues discussing technical drawings and diagrams in front of a screen.