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This paper aims to represent a novel framework for optimization of robotic handling from disarray to structure where the products are randomly distributed on a surface, the initial location of the products are known (with the aid of image processing, laser position sensors, etc.) and there is a set of final positions for the products.

Pick‐and‐place is one of the main solutions especially for the food products where the products are prone to damage, have adhesive surfaces and the grippers can be complicated. The aim of this paper is to maximize the utilization of the pick‐and‐place robotic system. In order to do so the handling process is modelled mathematically and the pick‐and‐place problem is formulated based on assignment problem where Hungarian algorithm is utilized to minimize the total distance travelled by the robot. Furthermore, a simulation program is developed to demonstrate the possible improvements of the algorithm in comparison with the existing algorithms.

Utilizing the proposed algorithm can significantly increase the utilization of robots in the pick‐and‐place operation.

The new optimization algorithm can be applied to any industry with pick‐and‐place where time efficiency and maximum utilization matters.

This paper aims to introduce and identify a new 3D handling operation (bin picking) for natural discrete food products using food categorisation.

The research shows a new food categorisation and the relation between food ordering processes and food categories. Bin picking in the food industry needs more flexible vision software compared to the manufacturing industry in order to decrease the degree of disarray of food products and transfer them into structure.

It has been shown that there are still manual operated ordering processes in food industry such as bin picking; it just needs new ideas of image processing algorithms such as active shape models (ASMs) on its development in order to recognise the highly varying shapes of food products.

This research was aimed at locating a new ordering process and proving a new principle, but for practical implementation this bin picking solution needs to be developed and tested further.

Identifying new ordering processes via food categorisation is unique and applying ASMs to bin picking opens a new industrial sector (food industry) for 3D handling.