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Gyermelyi has added a new pasta factory and warehouse equipped with leading-edge automation technology from ABB to help take productivity to the next level.

By fully automating production and packaging lines with flexible, easy-to-use ABB robots, Hungary’s Gyermelyi has doubled production capacity while maintaining the brand’s high reputation for quality.

ABB’s innovative solutions for Gyermelyi represent one of the most advanced production and packaging lines in Hungary’s growing food industry. According to the Hungarian Chamber of Agriculture, food and beverage is the second-largest employer and the third-biggest producer in Hungary’s manufacturing sector. However, the industry is under pressure to improve productivity in an increasingly competitive marketplace with rising labour costs.

ABB helped transform Gyermelyi’s production and packaging lines into fully automated systems, using technology such as user-friendly human-machine-interface (HMI) on robots, making the entire process more efficient and reducing the need for manual intervention during production. 

ABB designed and installed two high-performance sorting and palettising systems for the newly constructed factory, which include two box palletising and two bag palletising robots as well as one pallet sorting robot. The solution also includes product manipulating elevators, a flexible bag and box sorting system, and an automated wrapping and labelling system.

The new production and warehouse facility houses more than 3,000 stacking spaces that can also store double pallet racks. The small goods line has a capacity of 4000 kg/h, while the fibrous goods line has a 3500 kg/h capacity. ABB’s solutions will help boost the yearly capacity of the pasta factory to 70,000 tons. As a result, Gyermelyi expects to sell 36,000 tons of pasta this year.

Palletising robots offer tireless endurance for repetitive lifting while adding flexibility for diverse consumer needs.

Palletising robots offer tireless endurance for repetitive lifting while adding flexibility for diverse consumer needs.

“We know the diversity of our market, so we were looking for flexible solutions for the new palletising plant. When making our decision, in addition to the technical parameters of the system it was, of course, just as important that ABB has significant experience in palletising. ABB engineers and constructor partners have the necessary expertise, and their backup service in Hungary was also a key aspect for us,” said Csaba Pósfai, Director of the Gyermely factory.

Food processing across the globe is undergoing a rapid evolution as shifting buying habits are driving companies to offer a greater variety of foods and packaging, often tailored to seasonal specialities and more diverse consumer needs such as gluten-free, diabetic, etc. Manufacturers such as Gyermelyi are investing in solutions that can flexibly accommodate such diversity with efficiency while maintaining uncompromised quality and food safety. 

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