Key Safety Tips for Using Pick and Pack Robots
Pick-and-pack robots can transform your fulfillment speed, accuracy, and labor efficiency. But poor safety practices lead to downtime, injuries, and compliance violations. Many operations overlook safety during implementation, focusing solely on output gains. The reality is simple: without proper safeguards, your automation investment can turn into a liability.
Let's have a look at practical, high-impact safety tips for using pick and pack robots, helping you protect your team, comply with OSHA and ANSI standards, and optimize production without risking injury or unplanned stoppages.
Understand the Core Hazards of Pick and Pack Systems
Before deploying safeguards, you must identify potential risks. Pick and pack robots often operate in shared workspaces, which introduces several hazards:
Pinch points between robotic arms and fixed surfaces
Unexpected movements due to programming errors or sensor faults
Sharp end effectors or suction tools that can cause impact injuries
Collisions with mobile equipment like conveyors or AMRs
Electrical hazards from exposed or damaged cabling
Even collaborative robots (cobots) require hazard assessment. Safe automation starts with a clear map of physical and procedural risks.
Helpful Tips For Using Pick And Pack Robots
Given below are some of the practical ways of using Pick and pack robots:
Tip 1: Conduct a Full Risk Assessment Before Deployment
Every robot integration should begin with a documented risk assessment. This should include:
Task-specific hazard identification
Risk scoring based on likelihood and severity
Required safety controls (physical and administrative)
Utilize international safety standards, such as ISO 12100 and ISO 10218, to guide the process. In North America, align with OSHA 1910 Subpart O for machinery and ANSI/RIA R15.06 for industrial robots.
Involve engineers, operators, and safety officers early in the evaluation. Each stakeholder sees different risks that affect the overall safety plan.
Tip 2: Use Light Curtains and Area Scanners for Zone Control
Most pick and pack operations require human-robot interaction, particularly during packaging, replenishment, or quality assurance checks. To avoid collisions or unexpected motion:
Install light curtains to stop robot movement if someone enters a danger zone
Use laser scanners to monitor floor areas for human presence
Deploy pressure-sensitive mats around robot cells
These non-contact safety systems automatically halt robotic motion when thresholds are breached, preventing accidents in shared workspaces.
Make sure these systems meet Performance Level (PL) d or e, as required by ISO 13849-1 for safety-related parts of control systems.
Tip 3: Lockout/Tagout (LOTO) Procedures Must Be Enforced
Robots require power for motion, sensors, and control logic. Even during maintenance or programming, unexpected movement is possible.
To reduce this risk:
Train all technicians on LOTO protocols
Use keyed disconnects and clearly labeled kill switches
Verify that stored energy is fully discharged before any human access
Robotic LOTO procedures should include hydraulic, pneumatic, and electric energy sources. Review and re-certify all authorized personnel annually.
Tip 4: Train Operators on Emergency Stop (E-Stop) Systems
Every robotic cell should feature readily accessible E-stops that immediately disconnect the robot's drive power. Proper placement is critical:
Install E-stops at the operator control panel, gate entry, and inside the work cell
Use mushroom-style buttons with dual-channel wiring
Confirm E-stops are wired into the robot controller's safety circuit
Regularly test E-stops as part of your preventive maintenance checklist. Also, ensure that all floor workers are aware of their location and know how to activate them without hesitation.
Tip 5: Validate Robot Programming with Simulations First
Poor robot pathing or misconfigured sequences can result in erratic or unsafe movements.
Before deployment:
Run digital twin simulations of the full pick and pack workflow
Test motion paths using offline programming tools
Identify conflicts between robot arms, packaging stations, and human access zones
Simulations reduce programming errors that often cause near-misses in the real world. Validating robot behavior in advance avoids physical injury and equipment damage during commissioning.
Tip 6: Design for Passive Safety—Not Just Active Protection
Relying only on sensors and software creates risk if systems fail. Instead, include passive safety elements in your design:
Use rounded or soft-padded end effectors
Place high-risk movement zones away from human traffic
Reduce robot speed in collaborative modes
Install mechanical bump stops or guards where overtravel could cause harm
Passive safety remains active even if the system crashes or loses power, providing a critical backup layer that saves lives.
Tip 7: Keep All Safety Devices Maintained and Certified
Safety systems degrade over time. Dust, vibration, or electrical wear can make them unreliable.
Implement a scheduled safety audit plan that includes:
Testing light curtains and area scanners
Inspecting mechanical guards for looseness or damage
Verifying that emergency stops trigger the correct safety responses
Replacing worn-out interlock switches or wiring
Document every inspection and repair. In the event of an incident, maintenance logs may be required for OSHA or insurance reporting.
Tip 8: Avoid Overloading End Effectors or Grippers
Each pick-and-pack robot has a specified payload rating. Overloading the arm or using the wrong gripper for the task increases risk.
Common issues include:
Dropped packages that damage nearby workers or equipment
Overstrained joints that reduce braking performance
Misaligned items leading to repeat motion faults
Follow OEM load specs for each robotic arm and gripper. For multi-product workflows, use adaptive grippers that automatically adjust to the shape and size of the product.
Tip 9: Use Visual Indicators and Alarms
Keep your facility visually aligned with automation zones and hazard awareness using:
LED signal lights for robot state (idle, active, fault)
Warning beacons for start-up or shutdown sequences
Floor tape and signage to mark safe vs. restricted areas
This helps new staff, third-party technicians, and visitors navigate robot-heavy zones safely, even without complete system training.
Tip 10: Reassess Safety When Changing Workflows or Equipment
Many companies fail to update safety measures when:
Adding new products to the line
Integrating additional robots or conveyors
Changing pick-and-place sequences
Each change may introduce new pinch points, motion paths, or access zones.
Update your risk assessment and retrain staff after every major workflow or layout change. Don't assume existing protocols still apply.
Frequently Asked Questions (FAQ)
What safety certifications should pick and pack robots meet?
Pick and pack robots should comply with ISO 10218-1/2 for industrial robot safety and ANSI/RIA R15.06 in the U.S. Collaborative systems should meet ISO/TS 15066. Always verify that your integrator follows these standards during installation.
How often should safety systems like light curtains or scanners be tested?
Safety devices should be tested weekly or before each shift, depending on the device's usage intensity. Include these checks in your preventive maintenance schedule, and log each inspection for compliance tracking.
Can pick and pack robots work safely around human operators?
Yes, when configured correctly with safety zones, reduced speed modes, and reliable presence-detection systems like laser scanners or light curtains. Cobots also enable direct human-robot interaction, but they still require a thorough risk assessment.
What's the most common cause of robotic safety failures?
The most common causes are improper programming, disabled safety devices, and inadequate operator training. These failures are preventable with regular audits, real-world simulations, and certified technician support.
How do I implement lockout/tagout for robotic systems?
Use a documented LOTO procedure that isolates all power sources—electrical, pneumatic, and hydraulic. Train all maintenance staff on device locations, verification steps, and proper de-energization techniques. Apply locks and tags during any servicing activity.
Final Thoughts: Safe Automation Is Scalable Automation
Reliable throughput only occurs when workers feel confident, hazards are effectively contained, and systems are regularly audited and maintained. Poor safety leads to higher insurance costs, employee turnover, and machine downtime.
Protect your team and your production line by combining physical safeguards, intense training, and precision automation. The right robotic system doesn't just increase output; it minimizes human risk while scaling intelligently. If you're looking to integrate safe, AI-powered automation into your cannabis or CPG production line, contact Sorting Robotics today and see how safe, scalable filling works in real-time.
