As a leading player in the end-of-line packaging industry, Molenaar continues to push the boundaries of technology and system integration.

Efficiency, innovation and reliability are key to staying ahead in the food and beverage manufacturing sectors. As a leading player in the end-of-line packaging industry, Molenaar continues to push the boundaries of technology and system integration, providing flexible solutions to a variety of customers.

In this interview, Reinhard Watermeyer, commercial director at Molenaar, offers insights into the company’s approach to addressing challenges, driving innovation and ensuring seamless operations for their clients worldwide. From robotic palletizing advancements to innovative solutions, Molenaar’s expertise is shaping the future of end-of-line packaging.

Q. Can you provide an overview of Molenaar’s role in the end-of-line packaging sector within the food and beverage manufacturing industry?

A. Molenaar has established itself as a key player in the materials handling space, particularly within the end-of-line packaging sector. Our core strength lies in integrating various technologies, thanks to our extensive experience and strategic partnerships.

A significant focus of our work is robotic palletizing, where we are seeing the market trend toward automation. We’ve committed ourselves to innovating within this space, continually developing advanced palletizing systems that streamline operations and improve overall efficiency. These systems not only handle product movements between the palletiser and storage but are also designed to integrate seamlessly with broader manufacturing processes.

Q. What are the key challenges you face in ensuring the efficiency and reliability of end-of-line packaging systems?

A. One of the primary challenges we face is ensuring long-term efficiency, especially once our systems are in place. While we design and install standard machines that meet client specifications, ongoing operation depends largely on the client. The frequent turnover of personnel in our clients’ facilities can impact system efficiency, as new staff may not always be fully trained on how the machinery operates. To mitigate this, we provide comprehensive training and offer continued technical support. Our after-sales service is highly proactive, with regular check-ins and troubleshooting, ensuring that the machines maintain peak performance. Maintenance and system knowledge are key, and we prioritise these aspects through constant engagement with our customers, identifying potential issues before they escalate.

Q. How does Molenaar stay ahead of technological advancements in end-of-line packaging solutions?

A. Robotic palletizing remains central to our technological advancements. Our international presence gives us a broad perspective on global trends, allowing us to remain ahead of the curve. A pivotal step in this direction was the establishment of our Centre of Excellence for Robotic Application Development in the USA. This facility enables us to work closely with our customers, focusing on innovative applications that cater specifically to the growing demand for automation. By concentrating our efforts in the US, where the need for such solutions is particularly strong, we can refine and streamline our offerings before sharing the knowledge across our global offices, including those in South Africa. This collaborative knowledge-sharing allows us to continuously evolve and enhance our end-of-line packaging solutions.

Q. Can you discuss any recent innovations or technologies that Molenaar has integrated into its end-of-line packaging systems?

A. Our recent innovations are centred around robotic palletizing, particularly in the development of end-of-arm tooling. At our design lab in Tyger Valley, Cape Town, we’ve been working on simplifying the robotic gripper head, which is responsible for complete pre-formed patterns of trays.

The latest iteration of our gripper head is much more efficient, using fewer motors and electronics, while maintaining a high level of performance. By reducing complexity, we’ve managed to create a tool that is easier to maintain and operate, while still delivering superior results. This new gripper head is fully integrated with our robotics systems, resulting in increased operational efficiency and reduced maintenance requirements for our customers.

Q. How do you address the varying packaging needs of different food and beverage products?

A. We approach the varying needs of different products by dividing our efforts into specific vertical markets. We have dedicated applications teams that focus on the unique requirements of the food industry, and another team concentrating on the beverage industry. This allows us to understand the challenges and requirements of each sector, enabling us to provide tailored solutions. Our design and applications teams work closely to create systems that are optimised for each industry’s particular needs, ensuring that the solutions we offer are as effective and efficient as possible.

Q. Can you share some success stories where Molenaar’s end-of-line packaging solutions significantly improved a client’s production process?

A. We’ve had great success with a number of clients. One standout project was with a major food producer in the USA, where we implemented 24 palletizing systems for their canning operation. Our automated solution allowed the client to palletize filled cans with minimal human intervention. The system is fully integrated, with shuttles and conveyors transporting pallets to the wrapping stage, leaving only the final step of moving the pallet into storage to a forklift operator. This has resulted in a significant reduction in manual intervention, improved efficiency and minimised product damage.

Another success story is with a food producer in Johannesburg, South Africa.

We replaced six traditional gantry palletizers with two robotic palletizing cells, which now service six independent lines. This new system is fully automated, handling everything from palletizing to post-palletizing transport into the cold room. A particularly challenging aspect of this project was the development of the end-of-arm tooling, which we designed in-house. The system has been highly effective, increasing the client’s operational efficiency while reducing complexity.

Q. What are the key factors that differentiate Molenaar’s end-of-line packaging solutions from those of your competitors?

A. One of our key differentiators is the ability to offer a complete, integrated solution. Molenaar’s extensive in-house capabilities, combined with our partnerships with technology providers, enable us to deliver multifaceted solutions that are tailored to the needs of each client. We offer standardised products that can be adapted to meet specific requirements, ensuring flexibility while maintaining reliability. Our approach allows us to act as a one-stop supplier, providing everything from system design and installation to ongoing maintenance and support. This comprehensive service offering, coupled with our focus on innovation and efficiency, sets us apart from our competitors.