Tea Bag Packaging Process Automation Validated with Simulation | Case Study

The client planned a high-speed automated packaging process for tea bags. The line concept assumed several independent modules, each equipped with a feeder and a DELTA robot responsible for picking products and placing them into dedicated packs.

A key challenge was product orientation. Tea bags were leaving the feeder in different positions, while the final packaging process required each product to be placed in one defined orientation. At the same time, the line had to maintain high throughput and stable operation across multiple modules.

The concept therefore required verification before implementation, especially in the following areas:

• can DELTA robots keep up with the feeder speed,

• can wrongly oriented products be detected and turned fast enough,

• will the process remain stable at target performance,

• how many modules are needed to achieve the required OEE and throughput.

Key questions:

• Is the concept technically feasible at the assumed line speed?

• Will the DELTA robots achieve the required performance?

• Is the turning/orientation logic justified from the process perspective?

• What number of modules is optimal for the target OEE?

• Can the concept eliminate the reliability issues known from alternative mechanical solutions?

Simulation objectives:

• Validate the packaging concept before physical implementation

• Verify the performance of DELTA robots using supplier data

• Test the orientation and turning logic for tea bags

• Determine the optimal number of modules for the target OEE

• Confirm whether the entire concept can operate reliably under production assumptions

Nextomation developed a detailed production line simulation and digital modelling of the tea bag packaging process, recreating the planned modular line architecture and allowing the concept to be evaluated before physical implementation.

The modeled process reflected a system in which individual modules handled different product streams, with each module equipped with a feeder and a high-speed DELTA robot. The simulation reproduced product flow, orientation detection, turning logic and final placement into the target packaging format.

Particular attention was given to product orientation. A vision system was assumed directly at the feeder output, allowing correctly and incorrectly oriented tea bags to be distinguished. Products requiring reorientation were redirected to a dedicated turning mechanism and then returned to the main process flow for robotic pick-and-place.

Robot behavior was validated using manufacturer performance data, making it possible to determine whether the assumed feeder speed and handling logic were realistic. The model was also used to assess how many modules were required to achieve the target OEE and throughput while maintaining stable process performance.

This type of concept validation is particularly valuable in consumer goods manufacturing automation, where high production rates, repetitive handling operations and product variability require careful coordination between feeding, vision, robotics and packaging processes.

The project also demonstrates why simulation matters in automation design: critical assumptions regarding robot performance, product orientation logic, line capacity and the required number of modules could be verified with engineering data before the production system was built.

The same simulation-driven approach can support the development of custom automated assembly lines, where equipment interaction, cycle times, material flow and system capacity need to be validated before major investment and detailed engineering decisions are made.

A comparable application is presented in our container washing line simulation case study, where simulation was also used to evaluate system architecture, material flow and equipment performance before implementation.

1. Mappingthe modular packaging concept

The simulation model recreated the assumed line architecture with several packaging modules, feeders, robotic handling, and final placement logic.

2. Performanceverificationof DELTA robots

Using supplier-provided robot data, the simulation checked whether the DELTA robots could maintain the expected cycle rate and keep up with the incoming product flow.

3. Validationof product orientation logic

The model tested a concept in which the vision system recognized product orientation directly after the feeder, while incorrectly oriented tea bags were mechanically turned before final placement.

4. Comparisonwith less reliable alternatives

The simulation supported a concept based on controlled product turning instead of relying on more passive and failure-prone mechanical arrangements, which had previously caused frequent jams and downtime in similar applications.

5. Determiningthe optimal number of modules

The process was analyzed from the perspective of target OEE and required output, allowing the team to identify the most suitable number of modules for the planned packaging system.

The simulation confirmed that the proposed concept was feasible and provided a solid basis for engineering decisions.

Key outcomes included:

• identification of the optimal number of modules for the target OEE,

• confirmation of DELTA robot performance,

• validation of the product turning concept,

• verification that the packaging process assumptions were realistic,

• reduced technical risk before detailed design and implementation.

The simulation gave the client a reliable basis for evaluating the project before committing to implementation. It helped reduce uncertainty in a demanding, high-speed packaging application and supported decision-making with engineering data instead of assumptions.

The project demonstrated how simulation can:

• validate automation concepts early,

• reduce the risk of underperforming line architecture,

• support the selection of the right process structure,

• verify robot suitability before commissioning,

• improve confidence in investment and design decisions.

Thanks to simulation, the client could verify whether the planned tea bag packaging process would work under real operating assumptions.

The project confirmed not only the feasibility of the robotic concept, but also the validity of the product orientation strategy and the expected performance of the DELTA robots. As a result, simulation became a practical decision-support tool at the concept stage, helping reduce risk and define the right system architecture before implementation.