What We Review On Site
A line audit starts with a walk through your current packing and palletising area so we can see how product moves from the pack station to the end of line. We look at the conveyor layout, infeed and discharge points, pallet build pattern, stretch wrap area, bag handling, carton flow and the space available for a retrofit. The aim is to understand what can stay in place and where a robot or cobot can be added without upsetting production.
Every site is different, so each audit is tailored to that site.
- Existing conveyor route and product transfer points
- End of line palletising or packing method
- Available floor space, headroom and access for maintenance
- Current safety guarding and operator movement around the line
How The Audit Process Works
Once you send an enquiry through the contact form, we arrange a suitable site visit with your production, maintenance or engineering team. The visit is used to gather measurements, watch the line running at normal speed and identify where manual labour can be reduced without creating new bottlenecks. We do not assume a robot will fit just because the line is busy, we check the actual handling points first.
After the visit, we prepare a practical view of the retrofit options, including conveyor integration, controls changes, guarding needs and any operator changes that may be needed. If the line is already partially automated, we can assess how to tie new equipment into existing controls and keep the handover between machines clean.
- Initial enquiry and site visit booking
- Walkthrough of the line with your team
- Measurements, photos and process notes
- Review of retrofit options and next steps
Packing And Palletising Retrofit Options
Many sites do not need a complete rebuild. In a lot of cases, a retrofit can be added to the current packing or palletising line with the right support structure, guarding and control logic. Depending on the product and packing format, that may mean a robotic palletiser, a cobot for lighter loads, carton handling assistance or a simple change to conveyor sequencing. The point is to improve flow without forcing major plant changes.
We work with existing conveyors and nearby equipment so the new system fits the way your plant already runs. That includes infeed timing, pallet discharge, product staging and space for operators to safely move around the line. Where a site has limited room, we look carefully at compact layouts and service access before any design is signed off.
- Robotic palletising for cartons, bags or trays
- Assisted packing stations for repetitive hand packing tasks
- Conveyor integration for smoother product flow
- Controls changes to coordinate line timing and stops
Safety Guarding And Risk Assessment Support
Safety is planned into the retrofit from the start. A robot cell, cobot station or palletising area must be guarded correctly, with access points, stop functions and operator routes considered during the design stage. We support risk assessment work, but each site needs its own assessment because the hazards in a Durban food plant are not the same as those in a Pretoria warehouse or a Gqeberha manufacturing line.
The audit helps identify the places where guarding, floor marking, interlocks or access control may be needed. We also check how maintenance staff will enter the area, how product will be cleared after a stoppage and whether the current layout leaves anyone too close to moving equipment. This is where small layout changes can make a big differnce.
- Safety guarding design for robot and conveyor zones
- Support for site specific risk assessment
- Access planning for operators and maintenance teams
- Review of stop functions and safe restart procedures
What You Receive After The Visit
After the line audit, you receive a clear summary of what was seen on site and which retrofit options are worth pursuing. That gives you a sensible base for internal planning, budget discussions and production scheduling. If the line needs phased work, we can outline where the first change should happen so you are not trying to do everything at once.
The recommendation also considers installation practicalities such as shutdown windows, delivery access, spares planning and the need for operator training. For plants in Midvaal, East Rand or across the metro areas of Johannesburg and Pretoria, this kind of planning helps reduce disruption when the retrofit is put in.
- Line review summary and key findings
- Suggested retrofit path for packing or palletising
- Notes on guarding, controls and installation needs
- Practical next steps for management and operations
How To Prepare Your Team For The Audit
A good audit works best when the right people are present and the line is running in its normal state where possible. If you can, have production, maintenance and a supervisor on hand so questions can be answered on the floor. It also helps to keep recent product sizes, pallet patterns and downtime notes nearby. That way we can see the real issues, not just the ones that show up on paper.
There is no need to stop the entire plant unless your process requires it. We will guide the visit around your operating conditions and work within your shift schedule as far as practical. If you need support for a single line in Kempton Park or a wider review across multiple sites, the process is the same, with practical advice based on what is actually happening on site.
- Have line operators and maintenance staff available
- Share current product sizes, pack formats and pallet patterns
- Note any recurring stoppages or manual bottlenecks
- Allow space for measurements around conveyors and work areas
