Revolutionizing Seafood Production with Adaptive Robots

Flexiv’s Fish Shaping Solution combines computer vision and force control to ensure a consistent fillet size and form. (Image: Flexiv)

Robotic automation technology is reshaping food manufacturing, packaging, and handling by driving significant improvements in efficiency, quality, and flexibility. By integrating advanced artificial intelligence, computer vision, and proprietary force-sensing technology, Flexiv has introduced cutting-edge automation to the food processing sector.

Flexiv’s latest installation automates the handling of breaded cod fillets for one of Asia’s largest frozen food producers. Utilizing their Rizon 4 adaptive robots with customized end-of-arm tooling, Flexiv has fully automated the time-consuming task of shaping cod fillets — a process historically plagued by high staff turnover due to its repetitive and monotonous nature.

Tackling issues of high staff turnover and inconsistent product quality, Flexiv’s Fish Shaping Solution combines computer vision and force-control to ensure a consistent fillet size and form.

Previously, workers manually shaped each fillet being produced, however due to the sustained concentration necessary, this resulted in a high employee turnover rate.

“We learned that the shaping stage was difficult for our client to staff, so we used our adaptive technology to solve the problem while enhancing the process,” said Liang Mao, Flexiv’s New Market Solution Director. “Our solution ensures consistency, accelerates production, and upholds the highest quality standards — all while completing a task no one wants to do.”

Operating at a speed and consistency impossible for humans to achieve, Flexiv’s solution significantly boosts productivity while guaranteeing uniformity in the final product.

This uniformity is enabled not only through a consistent shaping pressure, but also a fully automated self-cleaning feature that removes food debris from the end-of-arm tool, to maximize operational efficiency and hygiene.

Flexiv’s shaping solution follows a structured, multi-step approach for seamless integration into any food production environment.

The process begins with a thorough survey of the client’s operations, allowing Flexiv’s experts to assess needs, identify pain points, and determine automation opportunities. A tailored solution, complete with scenario-specific tooling, was then developed in consultation with the client to address these challenges.

Flexiv’s “plug-and-play” design allows for rapid installation with minimal disruption to production lines. The initial prototype for the fillet shaping solution consisted of four robotic stations and was installed in just half a workday. Thanks to its modular design, the client was able to expand the installation from the initial four stations to 10, and eventually to 20 stations.

This efficient, scalable approach ensures swift project implementation with minimal operational disturbance. As the floor manager of the cod production line noted, “Our goal was to automate the shaping process without affecting production. Flexiv made it possible and proved their solution’s scalability.”

Flexiv’s shaping solution solves the high turnover rate of a labor-intensive role by completely removing the need for human oversight.

A task that previously required focus, attention to detail, and the ability to match the speed of the conveyor for hours on end has now been fully automated.

This has had a major impact on the client, as to attract workers to the shaping stations previously, they were forced to offer higher remuneration compared to other areas of the production process.

Even with higher wages, however, the client was still unable to adequately staff the position. This resulted in the production rate being slowed to match the throughput rate of the available shapers, which in turn led to other stations operating at reduced efficiency.

By simply switching the end-of-arm tooling, the robots can transition from shaping fish fillets to other food-processing tasks, product packaging, pick-and-place operations, or sorting. (Image: Flexiv)

A core pain point, the shaping process was a bottleneck in the truest sense of the word and caused considerable operational inefficiency. The inability to consistently staff the shaping position not only impacted productivity but also led to fluctuating product quality, as the remaining workers struggled to maintain the necessary level of precision over long shifts.

By implementing Flexiv’s shaping solution, the client was able to eliminate this bottleneck entirely. Capable of operating continuously, and at a consistent speed, the throughput rate no longer depends on human factors such as fatigue or staffing shortages. This has allowed the production line to run at optimal efficiency, with all stations throughout the facility operating at full capacity.

The automation of the shaping stations has also led to significant cost savings. Without the need to pay higher wages to attract workers to an undesirable position, the client has reduced labor costs while simultaneously boosting overall output. The precise, consistent performance of the automated system also means less waste and fewer rejections due to improperly shaped fillets, further improving the client’s bottom line.

Central to Flexiv’s fillet-shaping solution is the integration of computer vision and AI, which allows the 20 robots in operation to identify and select the fillets that require shaping in real time. Each robot, synchronized with the speed of the conveyor, uses its force-controlled end-of-arm tool to apply precise pressure, down to 0.03 Newtons, to avoid damaging the delicate fish.

This level of precision ensures that all fillets meet the producer’s exact specifications, delivering uniform portions as outlined on the packaging. Powered by edge computing, the robots make instantaneous decisions, adapting to changes in conveyor speed or the density of fillet placement. Over time, the adaptive AI system learns from any errors or bottlenecks, continuously optimizing the process.

One of the key advantages of Flexiv’s technology is its versatility. Each robot comes with a universal mounting flange, an integrated AI system, and various programming options, allowing it to handle a range of tasks, even those that require a sense of “touch” or “vision.”

By simply switching the end-of-arm tooling, the robots can transition from shaping fish fillets to other food processing tasks, product packaging, pick-and-place operations, or sorting. This flexibility maximizes return on investment for manufacturers, helping them stay competitive in a rapidly evolving market.

Flexiv’s system continuously gathers and analyzes production data, offering insights that can improve quality control and predict potential issues. This data-driven approach enables floor managers to track performance metrics, monitor equipment health, and predict maintenance needs, reducing downtime and ensuring smooth production, even in the face of unexpected challenges.

This article was contributed by Flexiv (Santa Clara, CA). For more information, visit here .