“It provides significant relief for our employees and has also contributed to increased efficiency in production."
Kristofer Ott Sutt
Metaprint AS – Tallinn, Estonia
Company
Metaprint AS
Production and Location
Tallinn, Estonia
Industry
Packaging
Technology
XXL Gantry Robot
In a nutshell
When you look into the production facility at Metaprint AS, you see a team working with precision and speed. Between pallets and printing machines, everything runs like clockwork – supported by an XXL gantry robot that places sheet metal blanks with millimetre precision.
Automation saves energy and time, especially during peak periods. Instead of a standard solution, Metaprint opted for a customised system from igus – cost-efficient, quick to implement and perfectly tailored to the requirements on site.
The challenges: precise loading and every movement must be careful
Metaprint AS is a traditional company from Estonia and ranks among the largest manufacturers of aerosol packaging in Europe. For the loading of its printing machines, Metaprint relies on an innovative solution: an XXL gantry robot from igus, specifically developed for heavy and repetitive tasks.
Variety in application – and every movement precise:
The automation solution is used in a demanding production environment where thin sheet metal blanks are processed. The robot's tasks are diverse and physically challenging:
- Loading printing machines with sheet metal blanks
- Precise positioning with a repeatability of ±0.5 mm
- Handling heavy materials up to 25 kg per blank
- Automated feeding instead of manual labor
Efficiency meets cost-effectiveness
The decision to use the XXL gantry robot was made not only because of its technical performance but also due to its cost savings of up to 60% compared to conventional solutions. Thanks to the plug-and- program function, the system was quickly and easily put into operation – ideal for medium-sized businesses with limited budgets.
Customized solution instead of a standard product
Together with igus, a tailor-made special solution was developed to perfectly meet Metaprint's requirements. The robot visually resembles a giant 3D printer and is equipped with high-quality components such as drylin linear units and E2i series energy chains – ensuring durable, quiet, and maintenance-free movements.
The solution: Automated loading with precision and efficiency
In order to reduce physically demanding tasks and optimise processes at the same time, an automated solution for loading printing machines was implemented. At the heart of the system is an XXL gantry robot, which was specially designed for handling heavy and sensitive materials.
With a working range of 4700 x 2600 x 900 mm and a repeat accuracy of ±0.5 mm, the robot precisely positions sheet metal blanks weighing up to 25 kg. A vacuum gripper ensures controlled and gentle handling – even at high cycle rates.
An integrated feeding system with movable suction grippers automatically feeds the blanks into the pressing area. Manual placement is completely eliminated, which not only improves ergonomics but also increases process reliability.
Thanks to the plug-and-program function, the system can be operated intuitively and adapted flexibly. The solution is cost-efficient, quick to deploy and ideal for environments with limited budgets and high automation requirements.
Key facts
Working space
4700x2600x900
Repeatability
0.5mm
Max. Payload
25 kg
Cost Savings
Up to 60%
Metaprint automates printig press loading with XXL gantry robots from igus
Before automation, loading the printing machine was a physically demanding process that had to be done manually. Today, an XXL gantry robot completes this task entirely – precisely, quietly, and almost without interruption. The result: noticeable relief for the team and greater flexibility in day-to-day operations. Thanks to the automated solution, a skilled worker can now be deployed elsewhere – a real advantage, especially for small teams with limited resources. Performance remains consistent, workforce requirements are halved, and at the same time, process reliability increases.
The robot operates with a repeatability of ±0.5 mm and moves sheet metal blanks weighing up to 25 kg in a controlled and efficient manner. An intelligent feeding system completely replaces manual placement – ensuring stable and secure processes.
Conclusion
Automation is not just about technical advancement – it also brings about noticeable changes to everyday working life. The introduction of the portal robot shows how targeted innovation not only speeds up processes but also creates space for new tasks. Where strength and coordination were once required, a system that impresses with its precision and reliability now takes over.
The decision to go with this solution wasn't just for the sake of it, but a strategic move: away from rigid processes and towards flexible use of resources. The result is a more robust operation that stays stable even when there's a staff shortage – and a team that can focus on what really matters.
