Automation is the key to supply chain sustainability

Dave Walsha, sales manager at precision drive system supplier EMS, explores the role of automation in creating a greener supply chain.

The supply chain accounts for more than 90 per cent of most consumer goods companies’ environmental impact, according to McKinsey & Company. If it is to achieve Net Zero targets, the UK needs to make changes at every stage of its supply chains.

Industry in the UK is no stranger to robots – there are currently 101 of them installed per 10,000 employees. While most manufacturers are investing in automation to achieve increased productivity, efficiency and product quality, the potential benefits to sustainability are largely misunderstood. As industry in the UK attempts to reduce its carbon emissions by at least two-thirds by 2035, automation may be the answer it’s been searching for.

Robots can get to work right from the beginning of the supply chain in manufacturing facilities. Manufacturers can employ robots to undertake predictable, physical work, such as welding, food preparation and packaging. These repetitive tasks comprise the majority of manufacturing – around 59 per cent of production activities could be feasibly automated.

When human workers undertake repetitive tasks, attention to detail can slip and mistakes are made. Typically, the defective product must be discarded, contributing significantly to the waste produced by factories. Manufacturers who adopt automated production lines gain a high level of control over the assembly process, which minimises waste from defective goods and ensures customers receive a high quality product.

Additionally, automated equipment can be configured to perform tasks with high accuracy, demonstrating repeatability that is unmatched by human workers. For example, an automated dosing pump can supply the exact amount of materials, such as adhesives, lubricants or sealants, required to the target product area. This ensures that no material is wasted, improving sustainability as well as reducing cost.

Energy efficient warehouses

Robots are also common within warehouses, with many facilities integrating some degree of automation. But to achieve ultimate efficiency, warehouse logistics must be fully automated.

Complete end-to-end warehouse automation has previously been hard to master, with lorry loading and unloading proving to be a sticking point. Artificial vision systems can have difficulty distinguishing where one box begins and another ends in a crowded trailer. Also, many robots may have difficulty sorting through a jumble of boxes if they have fallen over in transit, or trying to pick up an object with a complex shape.

Recent development of robots that can successfully unload and load lorries are now providing the final piece of the puzzle. These robots have the ability to lift heavy loads, yet can also delicately handle a fragile package, unlocking the potential of complete warehouse automation.

Once end-to-end automation is achieved, a warehouse unit can become a lights out facility. Humans are no longer constantly needed to maintain productivity, so the warehouse can operate in complete darkness. In non-refrigerated warehouses, 65 per cent of energy demand may be related to lighting, so lights out facilities offer an opportunity to make huge savings in energy.

Automated warehouses can also focus on taking storage upwards, as products do not have to be stored within human reach. Taking this approach means a warehouse can often achieve as much storage capacity as a conventional warehouse twice its size, while requiring significantly less land.

Precise packaging

In 2019, the EU generated 79.6 million tonnes of packaging waste, according to the latest data by Eurostat. Automated packaging machines can use sensors to detect the dimensions of an object, and then pack it into an appropriately sized boxes made from a cardboard sheet. The machines use small levers and paddles to fold the sheet into a box.

As the appropriate box size is calculated for each item, it ensures that no more packaging is used than is necessary. Additionally, packaging robots work precisely, ensuring there is no damage to the product or packaging, keeping waste to a minimum.

Powering sustainability

Automating the supply chain requires high quality motors. For applications as intricate as picking, packing and dispensing, motors need to be compact, so the automated machine can fit into tight spaces in factories and warehouses. They must also be low weight, allowing the robot to make quick and agile movements, as well as exhibit high power so the machinery can move heavy cargo.

EMS is the sole UK supplier of Faulhaber motors, which are renowned for their unbeatable power-to-weight ratio. The Faulhaber brushless motors are ideal for automated systems, as they provide a long life with a wide speed range.

In particular, the BXT series can deliver torque of up to 134 millinewton metres (mNm) thanks to its innovative winding technology. The multi-pole brushless motors are available in lengths as small as 14 millimetres, making them ideal for robots with small space requirements. All Faulhaber brushless motors also have a range of compatible motion controllers that create an advanced, programmable drives system with easy and accurate control that is simple to integrate into an automated system.

Thanks to recent advances in automation technology, the applications of robots in industry has expanded rapidly. As well as delivering increased productivity and efficiency, the benefits of complete end-to-end automation should not be overlooked for increasing sustainability in factories and warehouses. When powered by precise, powerful motors, robots can help us make our supply chain greener.