IntelliBreak is a fully automated robotic bag break system designed to eliminate the risks, inefficiencies, and mess of manual bag handling.
Engineered for high-throughput environments, IntelliBreak combines advanced robotics, AI vision, and customizable components to deliver unmatched performance in material processing.
Demo Unit Material Testing
Multi-wall Paper Bags | Powder Seasonings
Solution Overview
01
Robot
The Fanuc M-710/50M series 6-axis robot features a high payload capacity and a compact design. It is optimized for efficient bag handling and material discharge, ensuring high throughput in demanding environments.
02
Vision System
Powered by AI learning, the Vision System intelligently guides the robot to each new pick position on the pallet, ensuring accurate, efficient handling every time.
03
Bag Breaking Station
Provided by Material Transfer, the bag-breaking station is customized to fit the specific product and bag type you’re working with. We also offer pneumatic or mechanical conveyance options to seamlessly transfer materials, with screening devices available to reduce contamination risks.
04
Controller
This system, equipped with the R-30iB controller, is Ethernet-compatible for seamless integration and communication with other processes. An advanced DCS package safeguards the robot’s precise operating zone.
05
Safety Fencing
Safety Fencing creates a compact yet secure cell for optimal safety. Options like light curtains and area scanners can be used to tailor the safety measures to your specific facility needs.
06
End of Arm Tool (EOAT)
Each application is paired with the ideal EOAT, which includes external vacuum generation and mechanical actuation options. This enables secure handling across various bag types, weights, and materials.
07
Pick Position
This system can accommodate multiple pallet positions and easily adapts to pallets that aren’t uniformly stacked, making loading as hassle-free as possible.
08
Dust Collection
Dust collection is pulled from the outside perimeter of the bag break station to minimize housekeeping. A self-contained option is also available to reduce product loss and minimize cleanup.
09
Bag Discard Location
Once emptied, bags are directed to a discard location, with options for in-cell disposal, external conveyance, or compaction integration to streamline waste handling.
10
Footprint
The standard cell footprint is approximately 9’x12’, designed for seamless integration into space-constrained facilities without sacrificing performance.
Protect your team from strain, sharp tools, and hazardous materials.
Manual bag handling exposes workers to repetitive lifting, cutting, and airborne particles—leading to injuries and OSHA-reportable incidents. IntelliBreak automates the process and includes built-in safety features like interlocks and light curtains to reduce risk and support compliance.
Keep your facility cleaner and more compliant with less effort.
Powdered materials like flour, seasonings, and chemical additives create dust and spillage that impact sanitation and air quality. IntelliBreak’s dust containment system captures particles at the source, minimizing cleanup and supporting hygiene standards.
Maintain consistent production with automated unloading.
Manual unloading slows down operations and creates bottlenecks—especially in high-volume facilities. IntelliBreak keeps material flowing with reliable, repeatable performance across shifts and sites, helping you meet demand without delays.
See measurable returns through labor savings and reduced waste.
By automating repetitive tasks and improving material recovery, IntelliBreak lowers labor costs, minimizes product loss, and boosts uptime. Most facilities see a fast payback, especially those processing multiple pallets per day.
Take a look.
Automating bag breaking across key industries
Automated unloading for clean, consistent production
Reduces waste and improves plant hygiene and safety.
Hygienic Design
Manual bag handling introduces contamination risks, especially with ingredients like seasoning blends and dairy powders. These risks can lead to rejected product, regulatory issues, and lost revenue. IntelliBreak’s hygienic design—with food-grade surfaces and dust containment—ensures clean, compliant unloading from bag to mixer.
Dust Containment
Powdered ingredients like flour and sugar create airborne dust that’s hard to control. This dust affects plant cleanliness, product quality, and employee safety. IntelliBreak captures dust at the source, helping maintain a cleaner facility and reducing cleanup time.
Labor Reduction & Throughput Gains
Manually unloading 50-lb bags slows production and strains workers. This leads to injuries, inconsistent output, and higher labor costs. IntelliBreak automates the process, increasing throughput and freeing up staff for higher-value tasks—delivering measurable ROI.
Hygienic handling for pet-safe ingredients
Minimizes allergens and protects product integrity.
Hygienic Construction
Pet food facilities must meet hygiene standards comparable to human food plants. Contamination risks—especially in specialty blends—can compromise pet safety and brand trust. IntelliBreak’s stainless steel contact surfaces and sealed design protect product integrity from start to finish.
Allergen Control
Cross-contact between ingredients like chicken, soy, or fish can trigger allergic reactions in pets. Without proper separation, even trace amounts can cause serious health issues. IntelliBreak’s customizable zones and cleaning protocols help prevent allergen contamination and support safe production.
Operator Safety
Manual unloading of heavy bags exposes workers to repetitive strain and sharp tools. These risks increase in high-volume environments and can lead to costly injuries. IntelliBreak eliminates manual lifting and cutting, improving safety and reducing downtime.
Efficient additive handling across multiple sites
Improves throughput and reduces manual labor.
High Throughput
Feed additive facilities must process large volumes of vitamins, minerals, and medicated powders quickly. Manual handling creates bottlenecks and slows production. IntelliBreak automates bag unloading to maintain consistent flow and meet high-volume demands.
Dust Control
Fine powders from premixes and supplements generate dust that’s hard to contain. This affects air quality and increases cleanup time, especially in industrial settings. IntelliBreak’s dust collection system captures particles before they spread, improving safety and cleanliness.
Manual Labor Reduction
Handling hundreds of bags daily is physically demanding and time-consuming. This leads to operator fatigue, injuries, and high turnover. IntelliBreak reduces manual labor, improving safety and workforce efficiency while supporting scalable operations across multiple sites.
Safe, compliant handling for hazardous powders
Reduces exposure and supports OSHA/ISO standards.
Dust Containment
Chemical powders like waxes, adhesives, and pigments pose serious inhalation risks. Uncontrolled dust can lead to health hazards and regulatory violations. IntelliBreak’s enclosed systems and targeted extraction keep hazardous particles contained and compliant.
Operator Safety
Manual handling of corrosive or reactive materials increases the chance of exposure. Even brief contact can result in injury or contamination. IntelliBreak automates the process and includes built-in safety features like interlocks and light curtains to protect personnel.
Compliance Support
Chemical manufacturers must meet strict OSHA and ISO standards for hazardous material handling. Falling short can result in fines, shutdowns, or legal consequences. IntelliBreak includes a third-party machine safety risk assessment and engineered safeguards to support regulatory compliance.
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