AMRs are integral to production and warehouse automation, providing efficient, reliable, and flexible pallet handling solutions. To enable an AMR to work successfully, several additional features are required alongside the AMR such as pallet stations, charging stations, and conveyor stations. To understand how these systems work seamlessly together, we will look into each of these in more details.
AMR Pallet Stations
An AMR Pallet station provide a designated area where AMRs can load or offload full or empty pallets autonomously.
To load or unload a pallet from the pallet station, the AMR aligns itself with the pallet station using its precise navigation system to ensure accurate positioning. It then raises or lowers its platform depending on whether it is collecting or offloading a pallet.
AMR Charging Station
AMR charging stations are a vital component in maintaining continuous functionality. Strategically positioned throughout the facility, these stations feature docking interfaces that AMRs navigate towards autonomously when their batteries require recharging. Upon arrival, the AMR aligns itself with the charging station using its precise navigation system and engages with the charging interface. Once connected, the station supplies the necessary electrical power to recharge the AMR’s batteries efficiently.
Throughout the process, monitoring systems ensure optimal charging levels and battery health, providing real-time feedback to the warehouse management system (WMS) for comprehensive fleet management and operational continuity. This automated charging process minimizes downtime, enhances operational efficiency, and supports uninterrupted workflow management in dynamic warehouse environments.
AMR Conveyor Stations
The primary purpose of an AMR conveyor station is to enable seamless integration between AMRs and fixed conveyor systems.
When an AMR approaches a conveyor station, it uses its advanced sensors and navigation system to align precisely with the conveyor station. Depending on the setup, the AMR either transfers the pallet onto the conveyor station to enable it to be transferred to the fixed conveyor, or collects a pallet for transport to its designated destination.
The video below gives and overview of AMRs and how they work.
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As a Capex manager in the manufacturing industry, the importance of effective budget planning cannot be overstated. Capital budgets are the backbone of long-term growth, enabling companies to invest in new technologies, expand operations, and maintain competitive edges. Below we will look into essential and advanced methods for planning and allocating capital budgets to ensure that every pound is invested wisely, maximising returns and driving strategic objectives.
Strategic Alignment: The Foundation of Effective Budget Planning
Before diving into the numbers, it’s imperative to ensure your capital budget aligns seamlessly with the company’s overarching strategic goals. This involves:
Understanding Company Objectives: Whether it’s increasing production capacity, enhancing product quality, or expanding market reach, your capital investments should directly support these aims. Aligning projects with business strategy ensures that resources are deployed where they can create the most value.
Prioritising Projects: Not all projects are created equal. Rank them based on their potential impact on strategic goals. This prioritisation process often involves a combination of financial metrics and strategic value assessments, ensuring that critical initiatives receive the necessary funding. More information on scoring and evaluating capex investment opportunities is available here https://www.granta-automation.co.uk/news/what-is-the-best-method-for-scoring-and-evaluating-capex-investment-opportunities/
Comprehensive Forecasting and Financial Analysis
Accurate forecasting is the bedrock of effective budget planning. Employing advanced techniques ensures robustness in your financial planning:
Trend Analysis: Review historical data to identify trends in capital spending and project outcomes. This can highlight areas of consistent overspend or projects that consistently deliver above expectations.
Scenario Planning: Develop multiple financial scenarios (best case, worst case, and most likely case) to understand potential impacts. This proactive approach allows for better preparation and adaptability.
Sensitivity Analysis: Assess how changes in key assumptions (e.g., sales volume, cost of raw materials) affect project viability. This analysis helps in understanding the flexibility and resilience of your projects under varying conditions.
Capital Budgeting Techniques: The Heart of Investment Evaluation
To evaluate potential investments, use these standard and advanced capital budgeting techniques:
Net Present Value (NPV): Calculate the present value of cash flows minus initial investment. A positive NPV indicates a profitable project. NPV is widely regarded as one of the most reliable methods for evaluating long-term projects. More information on calculating NPV is available here https://www.investopedia.com/terms/n/npv.asp
Internal Rate of Return (IRR): Determine the discount rate that makes the NPV of cash flows zero. Projects with IRR above the cost of capital are desirable. IRR is particularly useful for comparing projects of different sizes and durations. More information on calculating IRR is available here https://www.investopedia.com/terms/i/irr.asp
Payback Period: Measure the time it takes for an investment to generate cash flows sufficient to recover its initial cost. While simple, it doesn’t account for the time value of money, making it less reliable for long-term projects. More information on calculating payback period is available here https://www.investopedia.com/terms/p/paybackperiod.asp
Profitability Index (PI): Divide the present value of future cash flows by the initial investment. A PI greater than 1 signifies a good investment. This metric is particularly useful for ranking projects when capital is limited. More information on calculating PI is available here https://www.investopedia.com/terms/p/profitability.asp
Advanced Risk Management
Every investment carries inherent risks. Identifying and mitigating these risks is crucial for safeguarding your capital investments:
Risk Assessment: Identify potential risks (e.g., market volatility, supply chain disruptions) and their impact on projects. Utilise risk matrices to quantify and prioritise these risks.
Contingency Planning: Allocate a portion of the budget for unforeseen events. This ensures projects can proceed smoothly despite setbacks. Establishing a contingency fund is a best practice in capital budgeting.
Diversification: Spread investments across different projects to minimise risk. Diversification reduces the impact of any single project’s failure on the overall portfolio.
Engaging Stakeholders for Collaborative Planning
Engaging stakeholders throughout the budgeting process ensures alignment and support:
Collaboration: Work with various departments (finance, operations, R&D) to gather input and align on priorities. Cross-functional collaboration can uncover synergies and streamline resource allocation.
Transparency: Keep stakeholders informed about budget decisions and rationales. This builds trust and ensures collective buy-in. Transparent communication fosters a culture of accountability and shared responsibility.
Continuous Monitoring and Control
Once the budget is set, continuous monitoring and control are essential to ensure adherence and adaptability:
Regular Reviews: Schedule periodic reviews to track progress against the budget. Adjust as necessary to stay on course. Regular check-ins help to identify and rectify deviations early.
KPIs: Establish Key Performance Indicators to measure the effectiveness of capital expenditures. Common KPIs include return on investment (ROI), cost variance, and project completion rates. KPIs provide quantitative measures of success and areas needing improvement.
Audits: Conduct regular audits to ensure compliance with budgetary guidelines and identify areas for improvement. Audits help to maintain financial integrity and accountability.
Leveraging Technology for Enhanced Planning
Modern technology can significantly enhance budget planning and allocation:
Budgeting Software: Utilise advanced budgeting tools and software for accurate forecasting, scenario analysis, and real-time tracking. Tools like SAP, Oracle, and cloud-based solutions offer robust functionalities for capital budget management.
Data Analytics: Implement data analytics to gain insights into spending patterns and identify opportunities for cost savings. Advanced analytics can uncover hidden patterns and predictive insights.
IoT and Automation: Invest in IoT and automation technologies to improve operational efficiency and reduce long-term costs. These technologies can lead to significant improvements in asset management and maintenance.
Emphasising Sustainability and Compliance
In today’s manufacturing landscape, sustainability and compliance are not optional—they are imperative:
Green Investments: Funding projects that promote sustainability and reduce environmental impact can also lead to cost savings and improved brand reputation.
Regulatory Compliance: Ensure all projects meet local, national, and international environmental regulations. Staying compliant avoids legal penalties and fosters community goodwill.
Conclusion
Effective budget planning and allocation are fundamental to the success of capital investments. By aligning with strategic goals, leveraging robust financial analysis, managing risks, engaging stakeholders, and utilising modern technology, Capex managers can ensure their capital budgets drive growth and innovation. Implementing these advanced methods will not only optimise your investments but also solidify your role as a strategic partner in your organisation’s success. Embrace these best practices to master the art of capital budget planning and lead your company towards a prosperous future.
If you would like to discuss any palletising or AMR/AGV applications, then feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.
Robotic palletisers are renowned for their exceptional reliability, making them a preferred choice across a wide range of industries. Their advanced technology, precision, and durability contribute to their robust performance. Here’s an in-depth look at the factors that make robotic palletisers reliable:
Precision and Consistency
High Accuracy: Robotic palletisers excel in placing product on pallets with high precision, ensuring consistent stacking patterns. This accuracy minimises the risk of product damage and enhances overall packaging quality.
Repetitive Task Mastery: Robots are designed to perform repetitive tasks with exacting consistency. This capability ensures uniform output quality and operational efficiency over extended periods.
Durability and Robustness
Industrial-Grade Components: Constructed with high-quality, industrial-grade components, robotic palletisers are built to withstand the demanding conditions of industrial environments. This robustness translates to longer operational life and reduced wear and tear.
Extended Longevity: With proper maintenance, robotic palletisers can provide reliable service for many years, often surpassing a decade of continuous operation.
Low Downtime
Minimal Maintenance Requirements: Robotic palletisers typically require less frequent and less intensive maintenance compared to conventional palletisers, reducing overall downtime.
Rapid Diagnostics and Repairs: Equipped with advanced diagnostic tools, robotic palletisers can quickly identify and address issues, minimising the time needed for repairs and maintenance. Systems that have a remote log in functionality for remote support greatly reduce downtime and increase reliability.
Adaptability and Versatility
Handling Diversity: Capable of managing a wide range of product sizes, shapes, and weights, robotic palletisers can easily adapt to changes in production without significant downtime or reconfiguration.
Ease of Reprogramming: The programmable nature of a robotic system allows for quick adjustments to palletising patterns or new product lines, enhancing flexibility and responsiveness to market demands.
Advanced Technologies
Integrated Sensors and Vision Systems: Advanced sensors and vision systems enhance the accuracy and efficiency of robotic palletisers, reducing errors and ensuring precise placement of boxes.
Seamless Automation Integration: Robotic palletisers integrate smoothly with other automated systems, ensuring synchronised operations and reducing bottlenecks in the production process.
Enhanced Safety Features
Comprehensive Safety Mechanisms: Equipped with protective enclosures, emergency stop functions, and sensors, robotic palletisers offer enhanced safety for operators and reduce the risk of accidents.
Reduction in Human Error: Automation significantly reduces the likelihood of human errors that can lead to operational downtime or product damage, further enhancing reliability.
Proven Track Record
Widespread Industry Adoption: Robotic palletisers have been widely adopted across various industries, demonstrating their reliability and effectiveness in diverse real-world applications.
Positive User Feedback: Numerous case studies and testimonials from users highlight the robust performance and reliability of robotic palletisers, reinforcing their reputation as a dependable automation solution.
Ensuring Optimal Reliability
Regular Maintenance: Adhering to a structured maintenance schedule is crucial to keeping robotic palletisers in optimal condition and ensuring their longevity.
Professional Installation: Proper installation and integration with existing systems by professionals ensure the palletiser operates seamlessly from the start.
Operator Training: Comprehensive training for operators on the use and troubleshooting of robotic palletisers is essential for maintaining smooth and efficient operations.
Selecting the Right System: Choosing a robotic palletiser that aligns with specific operational needs, production volumes, and box specifications ensures maximum efficiency and reliability.
Conclusion
Robotic palletisers are a cornerstone of modern automation, providing unmatched reliability through their precision, durability, and adaptability. Their advanced technologies, coupled with a proven track record in many different industries, make them a reliable choice for automating the palletising process. By ensuring regular maintenance, professional installation, and adequate operator training, businesses can maximize the reliability and efficiency of their robotic palletising systems, achieving consistent and high-quality results over the long term.
If you would like to discuss your specific palletising requirements and the best methods of automating your process, please contact us on 01223 499488 or helpline@granta-automation.co.uk and we will be happy to help.
As the pet foods industry continues to evolve, the need for efficient and reliable palletising solutions has never been more crucial. From handling a variety of packaging types to ensuring speed and precision, here’s a comprehensive guide to choosing the right palletiser for your operations.
Types of Palletisers
There are many different palletising systems on the market, each suited to different processes and product types. Below is an overview of some of the more common types:
Robotic Palletisers Robotic palletisers are highly adaptable, capable of handling different packaging formats such as boxes, bags, cans, and pouches. They are ideal for a wide range of applications, and are capable of palletising single items, rows, or whole layers.
Palletiser with easy programming software can be quickly reprogrammed by production staff for different box sizes and configurations; making them highly adaptable. Their programming flexibility allows for easy adjustments to stacking patterns and configurations.
Layer Formers Layer former palletisers are best suited to applications with consistent product shapes and sizes; palletising products in layers at very high speeds. New product setups and configurations typically require a programmer.
Collaborative Palletisers Collaborative palletisers are best suited for applications where products can be vacuum picked from the top. They are not suitable for underneath or bag gripping due to their low payload capabilities.
Despite being called collaborative, these systems typically need guarding or laser area scanning to comply with safety standards. This additional safety also allows the cobot to run at industrial speeds until the safety is compromised by a person entering the cell, at which point it will continue to run but at collaborative speeds.
Each system type has its unique advantages, and the choice depends on your specific palletising needs and production requirements.
Product Handling Capabilities
Palletisers in the pet foods industry need to accommodate various packaging types. Almost any type of product can be automatically palletised by using the appropriate gripper for picking and placing items onto pallets. Additionally, slip sheets can be automatically inserted between layers, and completed pallets can be shrink-wrapped automatically. Common products suitable for automatic palletising include:
Boxes/Cartons/Display Boxes
Bags/Sacks
Open-Top Boxes
Trays/Bale Arm Crates
Bottles
Cans
Pouches
Barrels/Drums
Collation/Transit Trays
Palletiser Gripper Types
The type of gripper required for palletising depends on the specific product, with many grippers also capable of handling slip sheets and pallets. Here’s a detailed look at different grippers and their applications:
Foam Vacuum Gripper: A foam vacuum gripper is best suited for flat-topped products like boxes, display boxes, cartons, and certain types of cans. This gripper utilises vacuum suction to securely lift and place items onto pallets.
Vacuum Row Gripper: A vacuum row gripper increases palletising speeds by picking and placing multiple items simultaneously. It is commonly used for boxes, cartons, and some cans, optimising throughput in high-volume operations.
Bag Gripper: For products like sacks and bags that cannot be effectively handled with vacuum suction, a bag gripper is typically used. This gripper features positioning pins, lifting pins, and a center clamp to provide stable support during handling.
Underneath Gripper: The underneath gripper has tines that go underneath the product and a clamping arm that clamps onto the top of the product whilst it is being lifted. This design is suitable for open-top plastic or cardboard crates, weak boxes, shrink-wrapped items, and products in transit trays.
Parallel Gripper: Distinguished by their two side plates that close in parallel, they are best suited to regular-shaped boxes that do not lend themselves to vacuum gripping.
Barrel Gripper: Barrel grippers are specifically designed with curved arms to clamp around barrels or drums securely, offering a reliable solution for items that cannot be lifted using vacuum technology.
Bespoke Gripper: In cases where standard grippers do not meet the requirements, bespoke grippers are custom-made. These are tailored for irregularly shaped or oversized items, such as large 25L bottles or products requiring specific lifting methods, like those with handles.
Watch some videos showing some of the different gripper types and products being palletised here.
Key Considerations
There are many different things that need to be considered when specifying a palletiser to ensure that is will meet your current needs and potential future requirements. Some of the key things to consider include:
Product Variety: Ensure the chosen palletiser can handle the full range of packaging formats used in your operations. Pet foods come in various packaging formats – bags, cans, pouches. Palletisers need to handle this diversity.
Speed and Efficiency: Match the palletiser’s speed with production demands to avoid bottlenecks and maximize throughput.
Automation Integration: Seamless integration with existing automation systems is crucial for efficient operation and control.
Scalability: Select a palletising system that can scale with your production growth, accommodating increases in volume and product types without requiring significant additional capital outlay.
This is just a brief overview of the many different things that need to be considered when specifying a palletiser system, and they are all explained in more detail here. There is also a downloadable Palletiser URS document available for you to download and modify to suit your specification, to ensure that you have covered everything when specifying your palletiser. It can be downloaded here.
If you would like to discuss your specific palletising application, feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.
In the ever-evolving landscape of production, warehousing and logistics, two priorities stand out: maximising efficiency and ensuring worker safety. Amidst the push for technological advancements, easy program and auto programming palletiser systems have revolutionised material handling and storage. This article explores the intricacies of palletising, its impact on operational efficiency, and its crucial role in mitigating Repetitive Strain Injury (RSI) among workers.
What is Palletising?
Palletising is the process of stacking products onto a pallet for storage or transportation. Often this task is performed manually, leading to inefficiencies and significant risks for workers. However, with the advent of easy program and auto programming palletiser systems, palletising has undergone a significant transformation.
Types of Palletising
Palletising methods can be broadly categorised into manual, semi-automatic, and fully automatic, each offering varying levels of efficiency, precision, and automation. Understanding these different systems is essential for determining the most suitable approach for specific operational needs. Here’s a closer look at each type:
Manual Palletising:
Involves workers stacking products onto pallets by hand.
Prone to human error, physical strain, and inefficiencies.
High risk of RSI due to repetitive lifting and stacking.
Semi-Automatic Palletising:
Combines human labour with machinery.
Machines assist with heavy lifting while workers handle the placement of goods.
Reduces physical strain but still involves repetitive tasks.
Fully Automatic Palletising:
Utilises robotic arms and automated systems to manage the entire process.
Minimises human involvement, ensuring consistency, precision, and efficiency.
Elimination of RSI risk due to no manual input.
Enhancing Efficiency through Automated Palletising
The implementation of automated palletising systems brings numerous advantages that significantly enhance operational efficiency:
Increased Throughput:
Robots can operate continuously without the need for breaks, dramatically increasing productivity.
Ability to handle higher volumes of products in shorter time frames.
Consistency and Precision:
Automated systems ensure uniform stacking, optimise pallet stacking patterns and minimise the risk of product damage during transportation.
Enhanced accuracy in handling delicate or perishable items.
Cost Reduction:
Although the initial investment in automated systems can be substantial, the long-term savings from reduced labour costs, decreased product damage, and improved operational efficiency are significant. This downloadable automation payback calculator will enable you to calculate the likely payback time of your investment. www.granta-automation.co.uk/automation-project-payback-calculator
Reduced need for overtime pay and removes the risk of worker injury-related costs.
Adaptability:
Traditional palletiser systems require 1-2 days to program and set up a stack pattern for a new product. They also require a skilled robot programmer, which can be costly and inconvenient.
Easy programming palletiser systems only take 5 minutes to set up a new stack pattern, and can be programmed by anyone.
Auto programming palletisers scan the product using a laser measuring system and then automatically create stack patterns without the need for human input.
Addressing Repetitive Strain Injury (RSI)
Repetitive Strain Injury (RSI) is a pervasive issue in production and warehousing environments, resulting from repetitive motions and prolonged physical exertion. Manual palletising, in particular, is a high-risk task due to the constant lifting, twisting, and stacking required. RSI can lead to chronic pain, decreased productivity, and increased healthcare costs. This downloadable RSI calculator will enable you to calculate the risk of RSI in your palletising process. www.granta-automation.co.uk/repetitive-strain-injury-assessment-tool-download
Mitigating RSI through Automated Palletising
One of the most significant benefits of automated palletising systems is their potential to reduce the incidence of Repetitive Strain Injury (RSI) among workers. By minimising or eliminating the physical demands of manual stacking, these systems help create a safer and more ergonomic working environment. Key strategies for mitigating RSI through automated palletising include:
Minimised Manual Handling: Automated systems significantly reduce or eliminate the need for manual stacking, thus lowering the exposure of workers to repetitive tasks that can lead to RSI.
Ergonomic Improvements: Semi-automatic systems can be designed to enhance ergonomic conditions, allowing workers to operate at comfortable heights and positions, reducing physical strain.
Task Rotation: Automation allows for better allocation of human resources, enabling workers to engage in a variety of tasks, thereby reducing the risk of repetitive motion injuries through varied physical activities.
Reduced Physical Strain: Machines handle the heavy lifting and repetitive movements, eliminating the physical strain on workers and removing the likelihood of injuries.
The integration of automated palletising systems in production, warehousing and logistics represents a significant leap forward in both operational efficiency and worker safety. By reducing reliance on manual labour and minimising repetitive tasks, these systems not only enhance productivity but also play a crucial role in mitigating the risks associated with Repetitive Strain Injury (RSI). As technology continues to advance, the adoption of automated palletising will undoubtedly become more widespread, setting new standards for operational excellence and worker well-being.
If you would like to discuss your specific palletising requirements and the best methods of automating your process, please contact us on 01223 499488 or helpline@granta-automation.co.uk and we will be happy to help.
Are you ready for the Christmas rush? These compact palletising systems can be leased for as little as £3.96 per hour! They start as small as a Smart car and are available in time for Christmas.
Improving throughput during peak production periods is crucial for maintaining efficiency, meeting customer demand, and maximising profitability. This often requires a strategic blend of process optimisation, automated technology, workforce management, and effective coordination. Here are some simple strategies that can be implemented to enhance throughput:
Process Optimisation
Streamline Workflows:
Identify and Eliminate Bottlenecks: Conduct a thorough analysis of your production processes to pinpoint bottlenecks. Implement solutions to alleviate these constraints and smooth the flow of operations.
Standardise Procedures: Develop and enforce standardised operating procedures (SOPs) to ensure consistency and efficiency across all production stages. SOPs help in reducing variability and increasing reliability.
Lean Manufacturing:
Minimise Waste: Adopt lean manufacturing principles to eliminate waste in all forms; whether it’s excess inventory, unnecessary movement, or inefficient processes.
Just-In-Time Production: Implement just-in-time (JIT) production techniques to reduce inventory costs and enhance responsiveness to customer demand. This approach ensures that materials arrive only when needed, reducing storage requirements.
Kaizen and Continuous Improvement:
Foster a culture of continuous improvement (Kaizen) where employees are encouraged to suggest and implement small, incremental changes. These small changes accumulate to significant improvements over time.
Workforce Management
Cross-Training Employees:
Enhance Flexibility: Cross-train employees to perform multiple roles, increasing the flexibility of your workforce. This allows for quick reallocation of labour to where it is most needed during peak periods.
Incentive Programs:
Motivate Performance: Implement incentive programs that reward employees for high performance and efficiency. Recognition and rewards can drive employees to maintain peak productivity.
Flexible Scheduling:
Adapt to Demand: Utilise flexible work schedules to ensure that labour is available during peak demand times. This might include staggered shifts, part-time work, or overtime as necessary.
Technology and Automation
Automation
Reduce Human Error and Increase Speed: Implement automation in repetitive and time-consuming tasks. Automated systems can operate continuously with high precision, reducing errors and increasing throughput.
Automated Palletising: Integrate automated palletising systems to handle the stacking and organising of products onto pallets. This reduces manual labour, speeds up the packaging process, and ensures consistent pallet quality.
Advanced Manufacturing Technologies:
Utilise Cutting-Edge Tools: Where possible, invest in advanced manufacturing technologies such as 3D printing, robotics, and CNC machines. These tools can significantly enhance production speed and accuracy.
ERP Systems:
Integrate Operations: Deploy Enterprise Resource Planning (ERP) systems to integrate production planning, scheduling, and inventory management. An ERP system provides real-time data and analytics, facilitating better decision-making.
Supply Chain and Inventory Management
Supply Chain Optimisation:
Ensure Timely Deliveries: Improve coordination with suppliers to ensure timely delivery of raw materials and components. Establish strong supplier relationships to secure priority during high-demand periods.
Resilient Supply Chains: Develop a resilient supply chain that can quickly adapt to changes in demand and supply conditions.
Inventory Management:
Smart Techniques: Implement inventory management techniques like ABC analysis to prioritise high-value items. Use methods such as safety stock and buffer inventory to handle unexpected spikes in demand without disrupting production.
Facility and Equipment Management
Preventive Maintenance:
Avoid Downtime: Schedule regular preventive maintenance to prevent unexpected equipment failures. Well-maintained machinery operates more efficiently and reduces downtime during critical periods.
Capacity Expansion:
Increase Production Capacity: Consider temporary or permanent capacity expansion by adding additional shifts, purchasing new machinery, or outsourcing parts of the production process.
Data and Analytics
Real-Time Monitoring:
Quick Issue Resolution: Implement real-time monitoring systems to track key production metrics. This enables quick identification and resolution of issues, minimising disruption.
Data Analytics:
Predictive Insights: Leverage data analytics to accurately forecast demand and plan production schedules. Data-driven insights can optimise resource allocation and improve overall efficiency.
Quality Control
Enhanced Quality Control:
First-Time Right: Implement stringent quality control measures to ensure products meet quality standards on the first pass. Reducing rework and defects directly improves throughput.
Communication and Coordination
Effective Communication:
Keep Everyone Aligned: Improve communication channels within the production team and across departments. Clear and efficient communication ensures everyone is informed and aligned with production goals.
Integrated Planning:
Collaborative Approach: Coordinate planning efforts across departments such as sales, marketing, and production. Integrated planning ensures that production aligns with market demand and organisational goals.
By implementing some, or all of these comprehensive strategies, you can significantly enhance throughput during peak production periods. This leads to better operational efficiency, reduced costs, and improved customer satisfaction, ultimately driving higher profitability and competitive advantage. Automated palletising, in particular, can be a game-changer by reducing manual labour, increasing speed, and ensuring consistency in product handling, further boosting overall throughput.
When using an automated palletising system, keeping production running during pallet changeovers is often essential for high-speed production lines. Here are some specific strategies that can be implemented to achieve continuous production with an automated palletising system:
Dual or Multiple Pallet Stations
Implementation: Equip the automated palletising system with dual or multiple pallet stations. This setup allows one station to be actively palletised while another is prepared or having its full pallet removed. This ensures that when one station pauses for changeover, the other can seamlessly take over without interrupting the production flow.
Examples: Safety systems like light curtains or shuttling gates or other safety interlocks can be integrated to allow the robot to palletise on one pallet position whilst a pallet is being loaded or removed from the other position.
Automated Pallet Dispensers with Pallet Conveyors
Implementation: Integrate automated pallet dispensers that can supply empty pallets to the palletiser and automated conveyor systems to transport pallets through to the palletiser and on to a safe zone after the pallet is stacked. These systems reduce the need for manual intervention, significantly speeding up the changeover process between pallets.
Example: An automated dispenser can hold a stack of empty pallets and a conveyor can feed them into the palletiser as needed. Once the pallet is stacked a conveyor system carries full pallets to an area where they can be removed from the conveyor without causing the system to stop palletising.
Buffer Systems
Implementation: Install buffer conveyors or accumulation before the palletising system on the product infeed to the system. These systems temporarily hold products during pallet changeovers, allowing the production line to continue running without interruption.
Example: A buffer product infeed conveyor with a holding capacity of several minutes’ worth of production can maintain the flow of products from the production line while a pallet changeover is in process. A buffering conveyor for full pallets will also allow the system to hold a certain number of full pallets that are waiting for removed without stopping they system from palletising.
Automated Guided Vehicles (AGVs) or Autonomous Mobile Robots (AMRs)
Implementation: Deploy Automated Guided Vehicles (AGVs) or Autonomous Mobile Robots (AMRs) to transport full pallets away from the palletising station and bring empty pallets to it. AGVs/AMRs can operate continuously as they can enter the palletiser safety zone whilst the robot is running, ensuring that pallets are always available for the palletiser.
Example: AGVs/AMRs that navigate the production floor, picking up full pallets from the palletiser and delivering them to the warehouse while simultaneously bringing empty pallets to the palletising area and the robot never has to stop during the pallet changeover as the AGV/AMR does not break the safety of the system.
As you can see, there are various different methods that can be implemented to ensure that production remains continuous during pallet change overs. The method best suited to your production will depend on your production speeds, product being palletised etc. If you would like to discuss your specific application, please contact us on 01223 499488 .
Typically, an underneath gripper would be used to palletise products that cannot be easily picked with vacuum from the top of the products, for example open-top trays, boxes with perforated lids, bottles etc. However an underneath gripper can be used for almost any application including standard tape top and bottom boxes. As nearly any product can be stacked with an underneath gripper, it works well for applications where there are mixed products needing to be palletised with the same palletiser. The video below shows an underneath griper palletising boxes and open top trays.
How an Underneath Gripper Handles Mixed Products
Integration with Production Line
Sensor-Based Detection:
As items come off the production line, sensors detect their type, size, and shape. This information is crucial for the gripper to adjust its configuration accordingly.
Dynamic Adjustment:
The gripper dynamically adjusts its forks or support platform based on the detected item. For boxes, it ensures a stable lift from underneath, and for open-top trays, it carefully supports the base to prevent any disturbance to the contents.
Smooth Transition:
The transition from lifting a box to lifting a tray is seamless. The system’s control software coordinates the movements of the gripper to switch modes efficiently without interrupting the flow of the production line.
Benefits of Using an Underneath Gripper in Mixed Production Lines
Versatility and Flexibility:
One of the primary advantages is the ability to handle different types of items without needing multiple grippers. This versatility reduces equipment costs and minimises the complexity of the automation setup.
Space Efficiency:
Using a single gripper system for both boxes and trays saves space on the production floor. There is no need for separate handling areas or additional machinery, allowing for a more compact and efficient production environment.
Reduced Downtime:
The adaptability of the gripper reduces the need for manual adjustments or changeovers between different types of items, leading to less downtime and higher overall productivity.
Improved Safety and Handling:
The underneath support provides a stable lifting method that minimises the risk of dropping or damaging items. This is particularly important for open-top trays that may contain delicate or loose contents.
Consistent Palletising:
The gripper ensures consistent placement of items on the pallet, maintaining uniformity and stability in the pallet stacks. This consistency is crucial for efficient storage and transportation.
Practical Considerations
System Design and Implementation
Customisable Configuration:
The gripper can be customised to handle specific dimensions and weights of boxes and trays commonly found on the production line. This customisation ensures optimal performance and reliability.
Integration with Existing Systems:
The underneath gripper can be integrated with existing conveyor and packaging systems, providing a streamlined addition to the current production setup.
Maintenance and Support:
Regular maintenance and calibration of the gripper and its sensors ensure continued precision and efficiency. Support from the manufacturer can provide ongoing improvements and troubleshooting as needed.
Conclusion
An underneath gripper provides an effective solution for palletising mixed items such as boxes and open-top trays coming off the same production line. By ensuring stable and gentle handling of diverse items, the underneath gripper helps maintain the integrity of products while optimising the palletising process. This integration leads to increased productivity, reduced operational costs, and a smoother workflow on the production floor.
If you would like to know more about mixed product palletising, please contact us on 01223 499488 .
Yes, a single robot can effectively palletise products from multiple production lines onto multiple pallet locations – watch the video below.
This capability can significantly enhance operational efficiency and flexibility in manufacturing settings. Here’s how it can be accomplished:
How It Works:
Advanced Programming: The robot is equipped with sophisticated programming that enables it to recognise products from different lines and understand where each product needs to be placed. This involves mapping out the exact positions of incoming products and their designated pallet location.
Integrated Conveyor System: Multiple conveyor belts are used to transport products from various production lines to a central pick-up area. This setup ensures that the robot can access products from all lines without needing to move extensively.
Vision Systems and Sensors: The robot employs advanced vision systems and sensors to identify and differentiate products. These systems help the robot determine the size, shape, and type of each product, ensuring accurate and efficient handling.
Gripper design: The robot’s gripper is designed to suit the variety of product types that need to be handled, such as boxes and trays. To maintain efficiency, the gripper will typically be designed to enable it to lift all of the different product types required, as gripper change overs during the palletising process reduce cycle time and efficiency.
Practical Steps:
Conveyor Design: The conveyor system is designed to converge products from different lines into a central location that the robot can easily access. This reduces the need for multiple robots and simplifies the overall layout.
Strategic Robot Positioning: The robot is then placed in a central position where it can reach both the convergence point of the conveyor belts and the palletising area efficiently. This strategic placement minimises the robot’s movement and maximises its productivity.
Safety Measures: Safety measures such as sensors, barriers, and emergency stops are integrated into the system to ensure safe operation. These measures protect workers and equipment, creating a safe working environment.
Example Workflow:
Product Convergence: Products from different production lines are transported via conveyor belts to a central pick-up area.
Product Identification: The robot uses its vision systems and sensors to identify each product and determine which line it came from and where it needs to be placed.
Pick-and-Place Operation: The robot automatically calculates motion paths using AI, and palletises according to lane priority. Efficiently picking and placing products one by one, or in multiples.
Benefits:
Increased Efficiency: By handling multiple lines with a single robot, the system reduces the need for multiple palletising setups, thereby streamlining operations and saving valuable floor space.
Cost Savings: Utilising one robot instead of multiple robots and associated equipment significantly cuts down on capital expenditures and operational costs.
Enhanced Flexibility: The system can easily adapt to changes in production lines and product types, providing a versatile solution that can handle a wide range of palletising tasks.
For more information, or to discuss you specific applications, contact us on 01223 499488 .
Granta Automation is the leading UK manufacturer of robotic palletisers, cobot palletisers, and compact and modular palletising systems, as well as automated container unloading, depalletising and cross-stacking systems, AGVs and AMRs. A top tier KUKA Platinum partner and Yaskawa partner with a huge number of installs and patented easy-programming palletising software and patented modular palletisers. Granta Automation design, build, install and support complete end-of-line palletising systems for manufacturers across the UK and Ireland. Established 2006.
Copyright 2026 Granta Automation Ltd. All rights reserved. Our palletising software and modular system are patented (GB2602358, EP3689539).
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