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“The Sandwich Factory”

Case study for Active8 Robots

The Sandwich Factory

Client: Bradgate Bakery, Samworth Brothers.


Sector: Food & drinks processing.

Application: Triangular sandwich picking, packing and inspecting.

Problem: High density labour dependency and high overheads.

Solution: Automated guarded industrial robot cell integrated with existing Trepko machinery to:inspect accuracy of diagonal cut and integrity of filling and assembly before erecting into upright position; receive and rotate sandwich halves180° before placing into skillets; and accommodate temporary mismatches in throughput between consecutive processes.


– Two robots: KUKA Agilus Hygienic Machines
– Two Keyence machine vision systems
– Two Auto-reject systems: one for misaligned sandwiches and the other for poorly erected skillets
– Patented twisted conveyor designed and built by Active8 Robots
– Bespoke food grade stainless steel rotating end of arm tooling designed and built by Active8 Robots

Patents: GB2567716 / GB2580484

How it works