Robotic Packaging Upgrade with Ertalyte®

Case Study: Ertalyte® Solves Robotic Packaging Wear Challenges for 24/7 Food Industry Automation

Industry: Food & Beverage Manufacturing
Application: End-of-Line Robotic Packaging Equipment
Client: Global Supplier of Case Packers, Sealers, and Palletizers
Solution Partner: Lehigh Valley Plastics

In the fast-paced world of automated food packaging, equipment uptime and material precision are mission-critical. A global OEM of end-of-line robotic systems came to Lehigh Valley Plastics to address premature wear on gripper arms and linear guides that were disrupting their 24/7 production lines. Their systems, originally using UHMW and Acetal plastic components, couldn’t keep up with the high-speed, high-cycle demands of modern case packing, sealing, and palletizing operations.

The Challenge

• Rapid Wear: Gripper pads and guide blocks made from UHMW and Acetal wore out every 6 weeks.
• Production Downtime: Frequent maintenance shut down packaging lines and reduced output.
• Component Deformation: Parts lost dimensional stability over time, causing misalignment.
• Hygiene Compliance: Materials had to meet FDA food-contact standards and withstand washdown cycles.

The Engineered Solution: Ertalyte® PET-P

Lehigh Valley Plastics collaborated with the customer’s engineering team to identify a material upgrade: Ertalyte® (PET-P). This semi-crystalline thermoplastic polyester delivers a unique combination of wear resistance, low moisture absorption, and tight-tolerance machinability—perfect for robotic assemblies in food-grade environments.

Why Ertalyte® Was Selected:

• Dimensional Stability: Maintains precision alignment in linear motion components over long production runs.
• Superior Wear Resistance: Outperformed Acetal by 3X and UHMW by 5X in controlled life cycle testing.
• Low Moisture Absorption: Resists swelling, warping, and microbial growth—ideal for humid or washdown areas.
• FDA-Compliant: Safe for direct food contact and compliant with sanitation regulations.

Prototyping & Testing Process

Lehigh Valley Plastics machined a full set of test parts in-house, including:

• Precision-milled linear guide blocks
• Custom-shaped gripper pads for robotic end-effectors

Validation took place across multiple robotic lines running live packaging operations. Mechanical fit, heat generation, moisture resistance, and wear profiles were all documented in real-time environments.

Project Results

• Service Life Doubled: Maintenance intervals increased from 6 to 12 weeks.
• Increased Throughput: Fewer breakdowns led to higher overall system uptime.
• Zero Tracking Drift: Ertalyte® held tight tolerances even under high-speed cycling.
• 6-Month ROI: The switch paid for itself via reduced downtime and part replacement costs.

“Lehigh Valley Plastics helped us identify the right material and supported us from prototyping through production. The Ertalyte parts have significantly improved the uptime and consistency of our robotic packaging systems.”
– Lead Mechanical Engineer, Global Packaging OEM

Looking to boost your automation system’s uptime and wear life? Talk to the experts at Lehigh Valley Plastics about material upgrades engineered for performance.

Frequently Asked Questions

What is Ertalyte® and where is it used?

Ertalyte® is a PET-P based engineering plastic ideal for precision parts in high-speed machinery. It’s widely used in food processing, automation, robotics, and linear guides due to its stability and wear resistance.

How does Ertalyte® compare to UHMW and Acetal?

Ertalyte® has significantly higher wear resistance and better dimensional stability. It resists moisture and retains tolerances better than UHMW and Acetal, especially in robotic or sanitary environments.

Is Ertalyte® FDA approved?

Yes, Ertalyte® is FDA compliant and suitable for use in food contact zones such as robotic gripping arms, guide rails, and conveyor components.

Can Ertalyte® improve robotic accuracy?

Absolutely. Its superior dimensional stability under load ensures robotic movement stays precise and repeatable even during high-cycle operations.

Case Study: Ertalyte® Improves Robotic Packaging Performance | Lehigh Valley Plastics