Start With the Line, Not the Robot
Every packing or palletising retrofit starts with the line that is already in place. We look at the current conveyor layout, product flow, infeed heights, pallet patterns, floor space and the points where manual handling is slowing things down. That early work helps us decide whether a cobot, a fully guarded robot cell, or a mixed approach is the better fit for the site.
For manufacturers in Kempton Park, Johannesburg, Pretoria, Durban, Cape Town and Gqeberha, the practical details matter.The aim is to improve output without forcing a complete plant rebuild.
Mechanical and Conveyor Integration That Fits the Plant
Most retrofit projects need the robot to work with conveyors, accumulation sections, guides, stops and transfer points that are already running. ReAutomated handles the integration so the new equipment and the old line operate as one system. That can include product timing, spacing, signal handshakes and ensuring cartons, bags or trays arrive in the right position for pick and place.
- Conveyor take-off and discharge coordination
- Product spacing and orientation checks
- Tooling and end effector interface planning
- Floor layout changes for access and maintenance
Where a line has been patched together over time, we map the real conditions on site rather than rely only on drawings. That helps avoid surprises during installation and keeps downtime to a manageable window.
Controls Integration and Simple Operator Handover
A retrofit only works properly when the controls are joined up. Our controls work covers the signals between the robot, conveyors, safety devices and the rest of the line so operators have a clear process to follow. We focus on straightforward control logic, useful fault messages and a handover that production teams can understand quickly.
Operator training forms part of the support package. The team on site needs to know how to start the cell, clear common faults, manage product changes and stop safely when required. We keep the guidance practical because the people running the line need answers that work on shift, not theory that sounds good in a meeting room.
Safety Guarding and Risk Assessment Support
Safety on a robotic packing or palletising line depends on the site. Each installation needs its own risk assessment based on the actual layout, speeds, access points and people movement in the area. ReAutomated supports the planning of guarding, interlocks, light curtains, fence lines and safe access points, but the final arrangement depends on the site conditions and the task being performed.
We work with general safety principles for industrial automation and make sure the retrofit is planned around controlled access, clear walkways and safe stopping arrangements. This is especially important where forklifts, pallet trucks and manual pallet changes happen in the same area. A good safety layout protects people and also reduces stoppages caused by awkward access or poorly placed guarding.
Commissioning Support That Gets the Line Running
Commissioning is where the details show up. We support the process of testing individual functions, proving the interfaces, checking the robot paths and confirming that the full line runs as intended. That includes dry testing, product trials, pallet pattern checks and fault recovery testing before handover.
- Mechanical checks and alignment
- Control loop testing
- Trial runs with live product
- Operator walk-throughs before handover
Sites in Gauteng and along the coast often face different pressures during startup, from high production demand to humidity and dust. We plan the commissioning work around those realities so the line can settle in properly and the team can build confidence with the new process.
After-Installation Support for Busy Production Teams
Once the retrofit is running, support does not stop at handover. ReAutomated provides maintenance support, breakdown assistance and spares planning to help keep the line available when it matters. That can include checks on wear items, advice on servicing intervals and help with identifying the parts that should be kept on site.
We also assist with line changes when product sizes, pallet patterns or packing requirements shift over time. A retrofit should not only solve today’s problem, it should also leave room for future adjustments without major rework. For manufacturers across South Africa, that practical support often makes the difference between a system that runs and a system that keeps running.
Choose the Right Level of Support for Your Line
Some projects only need help with one stage, while others need full support from survey to commissioning. If you are planning a robotic packing or palletising retrofit, the right starting point depends on your current equipment, layout constraints and production targets. ReAutomated can step in where you need it most, whether that is design, integration, safety planning or day to day support after startup.
Our base in Spartan, Kempton Park puts us close to the East Rand and within reach of major industrial areas across Johannesburg, Pretoria, Midvaal, Durban, Cape Town and Gqeberha. If you need a practical view on what will fit your line, send an enquiry through the contact page and we will assess the next step.
- Site Line Surveys
- Retrofit Design
- Conveyor Integration
- Controls Integration
- Safety Guarding Design
- Commissioning Support
- Maintenance Support