ABB helping Gyermelyi with Hungary’s most advanced pasta lines

By fully automating production and packaging lines with flexible, easy-to-use ABB robots, Hungary’s Gyermelyi has doubled production capacity while maintaining the brand’s high reputation for quality.

For nearly 50 years, Gyermelyi Company Group has been making Hungary’s favorite pasta, thanks to state-of-the-art technology that helped the company efficiently manage the entire product cycle. As demand from domestic and European markets continues to rise, Gyermelyi has added a new pasta factory and warehouse equipped with leading-edge automation technology from ABB to help take productivity to the next level.

Prodcution line at Gyermelyi. In 2019 the company plans on producing some 36,000 tons of pasta.
Prodcution line at Gyermelyi. In 2019 the company plans on producing some 36,000 tons of pasta.

ABB’s innovative solutions for Gyermelyi represent one of the most advanced production and packaging lines in Hungary’s growing food industry. According to the Hungarian Chamber of Agriculture, food and beverage is the second-largest employer and the third-biggest producer in Hungary’s manufacturing sector. However, the industry is under pressure to improve productivity in an increasingly competitive marketplace with rising labor costs.

ABB helped transform Gyermelyi’s production and packaging lines into fully automated systems, using technology such as user-friendly human-machine-interface (HMI) on robots, making the entire process more efficient and reducing the need for manual intervention during production.  

ABB designed and installed two high-performance sorting and palettizing systems for the newly constructed factory, which include two box palletizing and two bag palletizing robots as well as one pallet sorting robot. The solution also includes product manipulating elevators, a flexible bag and box sorting system, and an automated wrapping and labelling system.

The new production and warehouse facility houses more than 3,000 stacking spaces that can also store double pallet racks. The small goods line has a capacity of 4000 kg/h, while the fibrous goods line has a 3500 kg/h capacity. ABB’s solutions will help boost the yearly capacity of the pasta factory to 70,000 tons. As a result, Gyermelyi expects to sell 36,000 tons of pasta this year.

Palletizing robots offer tireless endurance for repetitive lifting, while adding flexibility for diverse consumer needs.
Palletizing robots offer tireless endurance for repetitive lifting, while adding flexibility for diverse consumer needs.

“We know the diversity of our market, so we were looking for flexible solutions for the new palletizing plant. When making our decision, in addition to the technical parameters of the system it was, of course, just as important that ABB has significant experience in palletizing. ABB engineers and constructor partners have the necessary expertise, and their backup service in Hungary was also a key aspect for us,” said Csaba Pósfai, Director of the Gyermely factory.

Food processing across the globe is undergoing a rapid evolution as shifting buying habits are driving companies to offer a greater variety of foods and packaging, often tailored to seasonal specialties and more diverse consumer needs such as gluten free, diabetic, etc. Manufacturers such as Gyermelyi are investing in solutions that can flexibly accommodate such diversity with efficiency while maintaining uncompromised quality and food safety.  

ABB Robotics is a pioneer in industrial and collaborative robots and advanced digital services. As one of the world’s leading robotics suppliers, we are active in 53 countries and over 100 locations and have shipped over 400,000 robot solutions in a diverse range of industries and applications. We help our customers to improve flexibility, efficiency, safety and reliability, while moving towards the connected and collaborative factory of the future.

ABB (ABBN: SIX Swiss Ex) is a pioneering technology leader in power grids, electrification products, industrial automation and robotics and motion, serving customers in utilities, industry and transport & infrastructure globally. Continuing a history of innovation spanning more than 130 years, ABB today is writing the future of industrial digitalization with two clear value propositions: bringing electricity from any power plant to any plug and automating industries from natural resources to finished products. As title partner in ABB Formula E, the fully electric international FIA motorsport class, ABB is pushing the boundaries of e-mobility to contribute to a sustainable future. ABB operates in more than 100 countries with about 147,000 employees.


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