System Overview
![SoapBottle_Icon Soap Bottle Icon](https://pearsonpkg.com/wp-content/uploads/2025/02/SoapBottle_Icon-e1739392305998.png)
Application: Case packing and palletizing for 5 different sizes of soap bottles (12, 15, 18, 24, 37.5 oz) in combinations of 4 and 6 products per case
Speed: 140 products per minute / 20-30 cases per minute
Unique Challenges: High line speed and product and case instability due to tall and skinny form factor of the bottles
Important to Customer: Machine uniformity with an easy user interface to minimize training needs and a single supplier to ensure optimal integration of all system components
Description of Operation
The line includes Pearson’s CE35-T Case Erector, a Lane Diverter, RTL-MX Top Load Case Packer, CS25 Case Sealer, and RPC-MX Palletizer with integrated Pallet Dispenser and Stretch Wrapper.
Key system highlights include:
- Case packer packs 4 cases simultaneously to lower the pick and place rate
- Fanuc robots with Allen-Bradley controls provide maximum uptime and minimal maintenance requirements
- Regenerative vacuum blower minimizes compressed air consumption
- Common and intuitive operator experience on all equipment
Empty cases, as small as 7x5 inches, are formed on Pearson’s CE35 Case Erector. They are then conveyed into the packing cell with their length dimension traveling parallel to flow. At the same time, soap bottles enter the cell in a single lane before being diverted into two or three lanes to prepare the pick pattern. With its custom end-of-arm tool, the robot picks enough product for up to four cases at once to achieve the desired throughput rates. The tool then automatically extends and gaps each product group. Mechanical fingers hold the case flaps open to ensure a smooth placement. Once full, the cases continue their journey to Pearson’s CS25 where they are top sealed with tape. Sealed cases then continue to the RPC-MX palletizer with integrated stretch wrapper. There, a pallet dispenser releases a pallet and conveys it to the pallet build station, where the robot picks and places multiple cases at a time. A Z-style pattern maximizes the pallet capacity. As soon as a layer of product is completed, the integrated stretch wrapper wraps the pallet up to the next the layer to ensure load stability. This process continues until the pallet is complete and fully wrapped.
System Components
The soap bottle pack and palletizing system is comprised of the following Pearson machines. Click on the image to explore the standard product features interactively or visit the product page for more details.
Case Erector
CE35
![RTL-HZ RTL-HZ Robotic Case Packer](https://pearsonpkg.com/wp-content/uploads/2021/05/RTL-HZ-300x169.png)
Case Packer
RTL-MX
Case Sealer
CS25
![RPC OU RPC OU](https://pearsonpkg.com/wp-content/uploads/2020/02/RPC-OU-300x169.png)
Palletizer
RPC-MX
User Centric Design
User centric design is about making the interaction with our machines as intuitive as possible. All Pearson machines are equipped with a uniform user interface that is highly intuitive following common website design principles, familiar icons, interactive maps and step-by-step graphical instructions. We want to reduce the learning curve for your operators and maintenance technicians, minimize the margin for human errors and make set up, changeover and fault recovery a fast and seamless process resulting in improved up time and equipment availability.
Digital Twin
![DigitalTwin](https://pearsonpkg.com/wp-content/uploads/2025/02/DigitalTwin.jpg)
Emulation of system components of the soap bottle line helped design, test and refine modifications in the virtual environment before implementing them in the field, reducing downtime for the customer and accelerating the implementation process.
The digital twin of the lane diverter helped reduce the machine’s footprint while maintaining case rate and the digital twin of the palletizer enabled us to optimize the machine’s performance through a new build process.