Blue Coconut imports raw coconut oil from the Pacific Islands in shipping containers, then refines and packs it for New Zealand supermarkets. Production runs in intense bursts — a container arrives, the team works through it, the warehouse fills as a buffer, and then the line goes quiet until the next shipment.
That rhythm made labour difficult to plan and expensive to retain. At the same time, supermarket shelf space is hard-won and costly to lose — Blue Coconut had to be able to demonstrate consistent supply, every time.
The constraint that shaped the solution: very tight floor space, and a specific packing process that an off-the-shelf line couldn't accommodate.
The solution — Phase 1: a bespoke packing line
FMIBI Automation designed and built a custom robotic packing line tailored to Blue Coconut's floor space and process flow. The system is unusual in that a single robot erects, fills, and closes the cartons — collapsing three traditional packing stations into one footprint of under 3 metres by 3 metres.
Because Blue Coconut runs multiple product sizes through the day, the line was engineered for SKU changeovers in minutes rather than hours, protecting throughput across mixed runs.
The solution — Phase 2: a Robotiq AX10 palletiser
Once the packing line had paid back its investment, Blue Coconut chose to extend the automation further with a Robotiq AX10 palletiser — selected for the same reasons as the packing line: compact footprint and flexibility. The AX10 integrated with the existing line and was fully operational in just over a day. It handles dual pallets for continuous production and stacks cartons up to 10 kg.
The outcome
A complete end-of-line solution — pack and palletise — running in a footprint most factories would consider impossible.
Reduced reliance on labour for irregular, hard-to-staff production runs.
Reliable supply to retain supermarket shelf space.
Fast SKU changeovers across the product range.
"Robotiq's compact palletising system fit seamlessly into our factory. Installation and integration with our packing line took just over a day, getting us up and running quickly, while the quality build and strong local support from FMIBI Automation gave us the confidence to invest. A great result all round."
- John Drew, CEO, Blue Coconut Limited
To learn more about how FMIBI Automation helps food and beverage manufacturers work smarter and faster with Robotiq automation, click here.
