Can a Palletiser Palletise Product Off Multiple Production Lines?

Posted on August 1, 2023 by Granta

Yes, a palletiser can palletise products from two or more separate lines, commonly referred to as “dual-line palletising” or “multi-line palletising”. This is a standard feature in many industrial palletising systems and is used to increase efficiency, optimize palletising operations, and reduce the need for additional palletising equipment.

In dual-line or multi-line palletising, products from two or more independent production lines are conveyed to the palletiser through their respective conveyors, and the palletiser can handle the multiple lines simultaneously. Here’s how the process typically works:

  1. Separate Conveyors: Each production line has its own conveyor system that feeds products to the palletiser. These conveyors typically run parallel to each other and can be set up side by side.
  2. Product Identification: The palletiser’s control system can identify the source of each product based on its origin line. This ensures that products from Line 1 are palletised together separately from products from Line 2, etc.
  3. Palletising Pattern: The palletiser’s software is programmed with the palletising patterns for each product line. Each line may have its unique stacking arrangement or palletising sequence.
  4. Robotic Palletising: The robotic arm of the palletiser picks up products from the various lines and places them onto the pallets based on their respective palletising patterns. With dual-line palletising, depending on the specific system setup, the palletiser will typically alternate between picking products from Line 1 and Line 2, ensuring a balanced and efficient palletising process. The system can also be set up to give palletising priority to one lane or the other, or to palletise on demand.

Benefits of dual-line and multi-line palletising:

  • Increased Throughput: By handling products from two or more lines at the same time, the palletiser achieves a higher throughput, reducing overall palletising time.
  • Space Optimization: A dual-line or multi-line palletising system allows manufacturers to use the same palletiser for multiple lines, optimizing floor space and reducing the need for additional equipment.

It’s important to ensure that the dual-line/multi-line palletising system is properly designed, and to ensure that the gripper head on the robot is suitable for picking and placing the products from the lines. The palletiser’s control system and software must be set up correctly to handle the different lines without any collision or safety issues.

A key factor to consider when choosing a double lane palletising system is the speed; the speed of the system will be defined by the number of cycles the robot can do in a minute multiplied by the number of products it can lift per cycle. Some systems have row gripping which enables the system to pick and place multiples of product, for a better understanding of this see https://www.granta-automation.co.uk/news/how-many-boxes-or-bags-per-minute-or-hour-can-a-palletiser-palletise/.  It is very important to ensure that the speed requirements including any pallet moving and slipsheet placement between layers is met, as having a dual lane system does halve the maximum speed per lane of a single lane system.

If you are considering implementing a dual-line or multi-lane palletising system, it’s best to consult with palletiser manufacturers or automation experts. They can provide guidance on the most suitable setup for your specific production requirements and ensure smooth integration with your existing production lines.

If you would like to discuss your specific application in more detail, please contact us on 01223 499488 or helpline@granta-automation.co.uk.

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How Many Boxes or Bags Per Minute or Hour Can A Palletiser Palletise?

Posted on August 1, 2023 by Granta

The number of boxes or bags a palletiser can handle per minute or hour depends on several factors, including the specific model and type of palletiser, the size and weight of the boxes/bags, and the complexity of the stacking pattern. Palletisers are machines used to automatically stack boxes or bags onto pallets for efficient transportation and storage.

There are different types of palletisers, such as robotic palletisers and conventional palletisers, each with its own speed and capabilities. High-speed robotic palletisers tend to have a faster throughput compared to conventional palletisers.

There are also a wide variety of griper head types available on a robotic palletiser, and each of these is able to lift different amounts of product per cycle. Depending on the product and gripper size, robot grippers can pick many products at a time speeding up the throughput of the palletiser, so an accurate calculation of boxes/bags per minute/hour will need to be done for your application to get the specific cycle time for your application.

This table does however show some typical speeds that can be achieve using different gripper types.  They are only approximate average speeds and as each application is unique the accurate speeds would need to be calculated based on the application.

The speed that the robotic palletising system can run in products stacked per minute is calculated as follows:

cycles per min with the robot and gripper
X
no of products picked by the gripper each cycle
=
palletising speed in products per minute

To convert boxes/bags per minute (BPM) to boxes/bags per hour (BPH), you can use the following formula:

BPH = BPM * 60

So, for example, a palletiser running at 100 BPM can handle:

100 BPM * 60 minutes = 6,000 boxes/bags per hour

Keep in mind that these numbers are general estimates, and actual performance may vary depending on the specific palletiser and the application. Additionally, the manufacturer’s specifications will provide the most accurate information regarding the palletiser’s speed and capabilities.

There are also several other contributing factors to consider that can affect the speed in addition to the cycle time of the palletising system such inclucing;

  • Conveyor speeds
    Often the restriction in speeds can be the conveyor system feeding the palletiser. Advanced conveyor systems are required when you get over 25 products per minute in order to control the product flow into the palletiser. An advanced conveyor system will orientate the product correctly whilst keeping it sequenced, and will stop/start as required for feeding into the palletiser system. Whilst a palletiser might be able to run at significantly higher speeds it is essential to get the conveyor system feeding the palletiser correct to enable the optimum performance of the palletising system.
  • Pallet feeding
    Another restriction in speed is the feeding of finished pallets out of the system and the feeding of new pallets into the system. A high speed palletising system will need to have an auto pallet feed system, where the new pallets can be fed into the cell without the palletising system having to stop.  This is often done by installing a auto pallet feeder which can be loaded form outside the palletising cell, and will then feed the emptly pallets into the cell via a conveyor system.  Filled pallets will also need to be able to leave the palletising cell without the palletiser having to stop palletising.  They is typically done using pallet conveyors and light curtains, which enable the pallet to safely leave the palletising cell without the palletiser having to stop.
  • Slipsheet placement
    Another restriction on the cycle time of a palletising cell is the time needed for slipsheet placement. Each slip sheet that is placed creates a break in the palletising process, and reduces the cycle time per hour by the amount of slipsheet placement/time taken to place the slipsheet per hour. Slipsheet placement therefore needs to be taken into account in any cycle time calculations.

If you could like help with calculating cycles times for your process, please contact us on 01223 499488 or helpline@granta-automation.co.uk.

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What Are The Benefits of a Modular Palletiser System?

Posted on August 1, 2023 by Granta

A modular palletising system offers several benefits that make it a popular choice for various industries. Here are some of the key advantages:

  1. Flexibility: The modular design allows for easy customization and configuration to match specific production requirements, product types, and palletising patterns. Companies can choose the appropriate modules and arrange them in different ways to achieve the desired palletising solution.
  2. Scalability: Modular palletisers can be easily scaled up or down to accommodate changes in production demands. As business needs evolve, additional modules can be added to increase throughput or reconfigured to suit new production layouts.
  3. Cost-Effectiveness: The modularity of the system enables companies to invest in only the necessary components, avoiding unnecessary expenses on features that may not be needed. This cost-effectiveness is particularly beneficial for smaller operations or those with varying production volumes.
  4. Easy Integration: These systems are designed for seamless integration with existing production lines and processes. The plug-and-play nature of modular components simplifies installation, reducing downtime during setup.
  5. Versatility: Modular palletising systems can handle various product types, sizes, and weights. With the ability to swap out end-of-arm tooling and adjust settings, the system can accommodate different products without major reconfiguration.
  6. Maintenance Efficiency: Individual modules can be easily serviced or replaced when needed, streamlining maintenance efforts and minimizing downtime. This is especially advantageous in industries where uptime is critical.
  7. Future-Proofing: As technology advances and industry requirements change, modular palletisers can be upgraded or enhanced by adding newer modules or integrating advanced software and controls.
  8. Reduced Footprint: The flexibility of modular palletisers often allows for more efficient use of floor space, making them suitable for facilities with limited space.
  9. Enhanced Safety: Modular palletising systems come with built-in safety features, ensuring compliance with industry regulations and reducing the risk of accidents during operation.
  10. Quick Deployment: Due to the pre-designed and tested nature of modular components, these systems can be deployed more rapidly than fully customized palletising solutions.
  11. Improved Productivity: The adaptability and efficiency of modular palletisers contribute to enhanced productivity and optimized palletising processes, resulting in increased throughput and reduced manual labour requirements.

The benefits of a modular palletiser system make it an attractive choice for various industries, including food and beverage, consumer goods, pharmaceuticals, logistics, and more. By leveraging modularity, companies can design and implement palletising solutions that align precisely with their specific needs, thereby improving overall production efficiency and cost-effectiveness.

To find out more about modular palletising systems, or if you would like to discuss your application in more detail, please contact us on 01223 499488 or contact us at helpline@granta-automation.co.uk.

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What Is A Modular Palletising System?

Posted on July 28, 2023 by Granta

 

A modular palletising system is a type of palletising system that is designed with modularity in mind. It consists of individual modules or components that can be easily combined, rearranged, or customized to create a palletising solution tailored to specific production needs. These modular systems offer flexibility, scalability, and adaptability, making them suitable for a wide range of industries and applications.

The key features of a modular palletising system include:

  1. Individual Modules: A modular palletising system is composed of distinct modules, such as conveyors, robots, pallet wrappers, pallet dispensers, and slipsheets. Each module serves a specific function and can be interchanged or upgraded as needed.
  2. Customizable Configurations: The modular design allows for various configurations, enabling the palletising system to be adapted to fit different production layouts, space constraints, and product types.
  3. Easy Integration: These systems are designed for straightforward integration with existing production lines or manufacturing processes. The modular components can be seamlessly integrated into the workflow without major disruptions.
  4. Scalability: As production needs change or expand, modular palletising systems can be easily scaled up or down by adding or removing modules as required.
  5. Simplified Maintenance: The modularity of the system simplifies maintenance and troubleshooting, as individual modules can be serviced or replaced independently.
  6. Quick Installation: Modular palletising systems often have faster installation times compared to fully customized systems since the components are pre-designed and tested off site prior to intall.
  7. Cost-Effective: By only selecting and installing the necessary modules, companies can avoid investing in unnecessary features, making these systems more cost-effective.

Modular palletising systems are available in various configurations, and the choice of configuration depends on the specific requirements of the application, such as production rate, product types, and pallet patterns.

These systems are commonly used in industries such as food and beverage, consumer goods, pharmaceuticals, and logistics, where versatility and adaptability are crucial to meet changing market demands.

The advantage of a modular palletising system lies in its ability to offer a tailored solution while providing the flexibility to adjust and expand the system in the future. Companies can work with palletiser manufacturers or automation experts to ensure that they design and configuration of the modular palletising system meets their unique production needs and optimizes palletising efficiency.

To find out more about modular palletising system, or if you would like to discuss your application in more detail, please contact us on 01223 499488 or contact us at helpline@granta-automation.co.uk.

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What is a Vacuum Gripper?

Posted on July 21, 2023 by Granta

 

Vacuum grippers are a type of end effector that uses suction to lift and manipulate objects. They are widely used for robotic palletising, which is the process of stacking and arranging products on pallets for transportation or storage. Vacuum grippers have many advantages over other types of grippers, such as:

  • They can handle a variety of objects, such as boxes, display boxes, cartons and some types of packed products and bags.
  • They can lift objects from above, without needing to grip them from the sides or below.
  • They can distribute the payload evenly across the object’s surface, avoiding deformation or damage.
  • They can be customized to fit different sizes and shapes of objects, by adjusting the number and position of suction cups or valves.
  • They can save energy and reduce noise, by using self-closing valves that only activate when needed.

A vacuum gripper works by using suction to lift and place objects onto a pallet. It consists of a electrical vacuum pump or a venturi vacuum pump connected to a vacuum head with suction cups or a foam pad. The vacuum gripper’s design and construction can vary depending on the application requirements. Some grippers have multiple suction cups arranged in an array for increased gripping capacity and flexibility, whereas other vacuum grippers have a foam pad. The vacuum pump creates a negative pressure inside the hose and the head, which causes the suction cups or foam pad to stick to the surface of the object. The robot arm then moves the object to the desired location on the pallet and releases the suction by turning off the pump or opening a valve.

Vacuum grippers are particularly useful in situations where traditional mechanical grippers may not be suitable, such as when handling delicate or irregularly shaped objects. They are commonly used in industries such as manufacturing, warehousing, and logistics.

Some examples of the different types of vacuum gripper are shown below.

Vacuum Layer Gripper

Row Vacuum Cup Gripper

Row Vacuum Gripper

Vacuum Bag Gripper

Vacuum Box Gripper

 

It’s worth noting that while vacuum grippers are efficient for many applications, they do have limitations. They rely on a certain amount of airtight seal, so they may not work effectively on some very porous or rough surfaces. Additionally, objects with irregular or curved surfaces may require specialized gripper designs or multiple suction cups to ensure a reliable grip.

Vacuum grippers are one of the best options for robotic palletising, as they offer versatility, speed, and reliability. They can improve the productivity and quality of the palletising process, while reducing the workload and risk of injury for human workers.

If you would like to discuss your application in more detail, please contact us on 01223 499488 or contact us at helpline@granta-automation.co.uk.

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What Weight Can a Robotic Palletiser Lift?

Posted on July 21, 2023 by Granta

The weight of product that a robotic palletiser can lift depends on the specific model and capabilities of the system. Robotic palletising systems are designed to handle a wide range of product weights, but there are limitations based on their payload capacity and mechanical capabilities.

Standard industrial robotic palletisers typically have a payload capacity of around 90-120kg, with heavy-duty robots having an even higher payload capacity of more than 1000kg. The weight of the gripper head also needs to be taken into account when calculating the payload capacity of the robot and the weight it can lift. Cobot palletisers have a lot lower payload of approximately 8-20KG, but realistically after the weight of the gripper is taken off, the payload is often 2kg less than this.

When selecting a robotic palletiser, it’s essential to consider the weight of the boxes you intend to palletise and ensure that the chosen robot can handle the maximum weight without exceeding its payload limits. Additionally, the size, shape, and stability of the boxes may also play a role in determining the palletiser’s performance and the overall stacking efficiency.

It is important to consult with the manufacturer or supplier of the robotic palletiser to get specific details about the model’s payload capacity and suitability for your application. They can provide guidance on the appropriate robot for your specific needs and help ensure smooth and efficient palletising operations.

If you would like to discuss your application in more detail, please contact us on 01223 499488 or helpline@granta-automation.co.uk.

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Problems With Industrial Robot Palletisers

Posted on July 18, 2023 by Granta

Industrial robot palletisers, like any complex machinery, can face several problems that can affect their performance and efficiency. Some of the common issues associated with industrial robotic palletisers, and their potential solutions include:

1. Programming errors

Problem: Incorrect or incomplete programming can lead to robotic palletisers not functioning as intended. This can result in errors in picking, placing, or stacking products, leading to misaligned or unstable pallets.

Solution: Ensure that the robotic palletiser is programmed correctly and that the software is up to date. This may involve working with experienced programmers or collaborating with the manufacturer to optimize the programming for your specific application. There are also systems available that have a tried and tested ‘easy programming’ software which helps to eliminate errors. Also, ensuring that the palletiser system has been commissioned and tested at the integrators site before being installed on your site will minimise the risk of programming errors occurring.

2. Mechanical failures

Problem: Robotic palletisers rely on various mechanical components, such as motors, gears, belts, and grippers, to perform their tasks. These components can experience wear and tear over time, leading to malfunctions, breakdowns, or reduced accuracy. Failure to perform routine maintenance tasks, such as lubrication, inspection, and cleaning, can result in increased wear and tear, decreased accuracy, and eventually, breakdowns.

Solution: Regular maintenance is crucial for the smooth operation of robotic palletisers. Implement a proactive maintenance schedule to keep the robotic palletiser in optimal working condition. This includes routine inspections, safety checks, lubrication, cleaning, and replacing worn-out components. Adherence to the manufacturer’s recommended maintenance guidelines is essential.

3. Sensor malfunctions

Problem: Robot palletisers often use sensors to detect and locate products, pallets, or obstacles in their workspace. If these sensors become faulty or misaligned, it can result in errors during the picking and placing process, leading to misplaced or dropped items.

Solution: Regularly clean and inspect the sensors to ensure their accuracy. Ensure that sensors have not got knocked or moved, and if any sensors are malfunctioning or misaligned, they should be promptly repaired or replaced.

4. Pallet or product variations

Problem: Industrial environments often involve handling a wide range of products with different shapes, sizes, and weights. If the robot palletiser is not designed or programmed to accommodate these variations, it may struggle to properly grip, lift, or stack certain products, causing errors or product damage.

Solution: If the robot palletiser struggles with handling certain products, consider adjusting or replacing the gripper to accommodate different sizes, shapes, or weights. Gripper customisation can improve the palletising process and reduce errors. If you are considering a new palletiser ensure you scope for the full range of products and ask for a demo with your products on a system before purchasing.

5. Integration challenges

Problem: Integrating a robot palletiser into an existing production line can present technical challenges. Incompatibilities with existing equipment, software, or control systems can lead to difficulties in achieving seamless integration and may require additional modifications or adjustments.

Solution: Ensure proper connectivity, compatibility, and integration to prevent communication issues. Plan any software link up required in advance of installation. Collaborate with suppliers and technicians and establish a good working relationship with the manufacturer or supplier of the robotic palletiser. They can provide valuable support, guidance, and troubleshooting assistance. Their expertise can help diagnose and resolve specific issues quickly and effectively.

To safeguard your robotic palletising system against these issues, it is important to ensure the system has been properly programmed, perform regular maintenance, and provide necessary training to operators. Additionally, involving experienced technicians and collaborating with the manufacturer or supplier of the palletiser can help diagnose and resolve specific issues efficiently. By doing this, you can enhance the performance, reliability, and efficiency of industrial robot palletisers, leading to smoother operations and improved productivity in your facility.

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Can You Automatically De Stack from a Pallet onto a Machine

Posted on June 30, 2023 by Granta

Yes, it is possible to automate the process of stacking items from a pallet onto a machine; this process is often known as depalletising or pallet de-stacking. It is effectively the reverse operation of palletising product, and automating this process can significantly improve efficiency, speed, and accuracy in industrial processes.

Depalletising is typically performed where the items need to be unloaded from the pallet and further processed, distributed, or placed into another system or production line. There are various methods and technologies that can be used to achieve automated de-stacking. Here are a few examples:

  1. Robotic depalletising: Robotic depalletising involves the use of a robotic arm or gantry systems to unload items from the pallet. These robots can be programmed to a pre-set stack pattern or can be programmed to identify and locate the items on the pallet using sensors, cameras, or other detection mechanisms. It will then grip and lift them, and place them onto a conveyor or other downstream equipment. Typically, a vacuum pick gripper is used for robotic depalletising and will either pick product singularly or in multiples depending on the product and speeds required. Robotic depalletising offers high speed, precision, and efficiency, making it suitable for high-volume operations or repetitive tasks.

  2. Layer depalletising: Layer depalletising involves removing entire layers of items from the pallet simultaneously. It often employs mechanical or robotic systems that can lift and transfer an entire layer of items onto a conveyor or other equipment. Layer depalletising is efficient and can be suitable for operations where items are uniformly stacked on the pallet. Once the product is placed on the conveyor, devices such as pushers, diverter arms, or pneumatic actuators that push or separate the items from each other, are be used to separate the product as required.

  3. Push-off depalletising: Push-off depalletising utilizes mechanical devices to push or slide items off the pallet. This method is commonly used for items that have a low coefficient of friction, such as cases or boxes. The mechanical device pushes the items in a controlled manner, allowing them to slide off the pallet and onto a conveyor or other equipment. Once the product is placed on the conveyor, devices such as pushers, diverter arms, or pneumatic actuators that push or separate the items from each other, are be used to separate the product as required.

These are just a few examples of automated systems that can be used for de-stacking items from a pallet into a machine. The specific choice of automation method depends on factors such as the type of items being depalletised, the desired speed and precision required, and the available budget. Implementing automated de-stacking systems often requires careful planning, integration, and customization based on the specific requirements of the operation to ensure that you get the best outcome for your requirements.

If you would like to discuss your application in more detail, please contact us on 01223 499488 or contact us at helpline@granta-automation.co.uk.

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Can A Palletiser Stack on Different Sized Pallets?

Posted on June 28, 2023 by Granta

Yes, a palletiser can stack products on different sized pallets. Palletisers are designed to handle various pallet sizes and configurations to accommodate different packaging requirements and industry standards. The specific capabilities of a palletiser depend on its design and features.

In the UK, the most commonly used pallet is the standard wooden pallet known as the ‘UK Standard Pallet’ or ‘Chep pallet’. The dimensions of the UK standard pallet are 1200 mm x 1000 mm (47.24 inches x 39.37 inches). The Euro pallet is also prevalent in the UK, especially in European trade. This has dimensions of 1200 mm x 800 mm (47.24 inches x 31.50 inches). 

Most palletisers are equipped with auto adjusting mechanisms that allow them to adapt to different pallet sizes. These adjustments ensure that the palletiser can properly stack and arrange the products on the pallet, regardless of its size. Some of the key factors that need to be considered to enable the palletiser to stack onto different sizes of pallet are:

  • Software: Palletisers are typically equipped with an HMI, which allows for programming and customisation. The operator can input the dimensions of the pallet being used into the HMI system. The software then adjusts the movements and stacking patterns of the palletiser accordingly to ensure proper alignment and stacking on the specific pallet size. On some palletiser systems, the pallets sizes are already saved and stored in the program; enabling you to simply select the correct pallet size and the palletiser software will then auto generate the most efficient stack pattern.
  • Where the palletiser is stacking on to pallet stack positions on the floor, the positioning of these pallet stack positions needs to be carefully considered.  This is due to the fact that for each of the different pallet sizes that the palletiser is going to be stacking, there needs to be enough space for each pallet type to be placed, and there also needs to be space around the stack position to allow for any overhang of the robot gripper as it stacks the pallet.
  • If the pallets are fed into the palletising system by auto feed conveyors, the width of the conveyor will define the largest pallet size that can be used. It is important to ensure that the conveyor system will work for the largest pallet size you wish to palletise onto.
  • Automated pallet feeder systems typically only take one size of pallet. Some automated pallet feeders are adjustable, but you would normally need a separate pallet feeder for each size of pallet.
  • If the system is a robotic palletiser, then the reach of the robot needs to be considered. Some smaller robots and cobot palletiser systems may not have enough reach on the robot for UK standard or Chep pallets.  This is something that especially needs to be considered if the palletiser is manufactured in Europe as it is likely to have been designed for palletising onto Euro pallets that are smaller in size than the UK standard pallets.
  • Another factor that needs to be considered when purchasing a palletiser to stack onto different sizes of pallets is how does the product sit on the pallet.  For example; do the boxes/bags/product overhang the side of the pallet? What height is the finished pallet stack?  All of these factors affect the reach of the palletiser and positioning of the pallet that the product is going to be palletised on to.
  • There are many different types of pallet construction. The pallet construction type and quality of construction is very important in an automated palletising system. For example; if the pallet has full perimeter boards around the base, a standard conveyor system will work for transferring the pallet through the palletising system.  However, if the pallet just has legs, then a different type of conveyor system may be needed to the traditional roller conveyors that are typically used in a palletising system as the legs of the pallet would just jam between rollers.

It’s worth noting that some palletisers may have limitations on the range of pallet sizes they can handle. For example, a particular palletiser may have a minimum and maximum pallet dimension specified by the manufacturer. It’s essential to consult the equipment specifications or contact the manufacturer to ensure that a palletiser can accommodate the specific pallet sizes you intend to use.

If you would like to discuss your application in more detail, please contact us on 01223 499488 or contact us at helpline@granta-automation.co.uk.

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Advantages and Disadvantages of Automated Palletisers

Posted on June 23, 2023 by Granta

Automated palletisers offer several advantages and disadvantages. However, each automated palletising application is unique, so there may be other advantages or disadvantages applicable to your situation that are not listed here.  Below are some of the key advantages and disadvantages of automated palletisers:

Disadvantages of Automated Palletisers:

Some of the key disadvantages of automated palletisers are listed below, however depending on the type of system you purchase and the company you purchase from, these disadvantages may not all apply.

  1. High Initial Investment: Implementing an automated palletizing system typically requires a significant upfront investment. The cost includes purchasing the equipment, installation, and integration with existing infrastructure. For small businesses or those with limited budgets, this initial investment may be a deterrent.  However, automated palletising systems are also available on leasing schemes which eliminates the requirement for any initial capital outlay.
  • Maintenance and Technical Support: Automated palletisers require regular maintenance to ensure optimal performance. They have complex mechanical and electrical components that may require specialized knowledge or technical support for repairs. Businesses need to budget for ongoing maintenance costs and have access to trained personnel or reliable service providers. Typically, an automated palletising solution will come with a support contract in place to ensure that the system is regularly checked and maintained.
  • Limited Flexibility for Irregular Products: While automated palletisers offer flexibility for a wide range of products, they may have limitations when it comes to irregularly shaped or fragile items. Certain products may not fit within the standard parameters of the palletiser, requiring manual intervention or alternative palletising methods.
  • Initial Setup and Programming: Setting up an automated palletising system and programming it to accommodate specific products and stacking patterns can be time-consuming. It may require technical expertise and thorough testing to ensure the system operates efficiently. Changes in product specifications or stacking requirements may also require reprogramming, which can lead to downtime and temporary disruptions. However, there are palletising systems on the market that have easy programming software as standard, enabling your factory staff to reprogram the robot for different product sizes quickly and easily.

Advantages of Automated Palletisers:

Automated palletisers have many different advantages, and the benefits for your company will be determined by your palletising requirements and how these will be met.  However, some of the more common advantages are listed below.

  1. Increased Efficiency: Automated palletisers can significantly improve the efficiency of palletising operations by handling high volumes of products at a faster rate compared to manual labour. They can work continuously without the need for breaks, resulting in increased productivity.
  • Consistency and Accuracy: Automated palletisers ensure consistent and accurate pallet stacking, minimising errors and reducing the risk of damaged products during transportation. They can precisely position each item according to the predefined stacking pattern, optimizing space utilization.
  • Reduced Labor Costs: By automating the palletising process, businesses can reduce their reliance on manual labour. This can lead to significant cost savings in the long run, as automated systems require less manpower, no breaks, and eliminate the need for manual lifting, which therefore reduces the risk of workplace injuries occurring.
  • Flexibility and Adaptability: Many automated palletisers are designed to handle a wide range of product types, sizes, and weights. They can be easily programmed by factory staff for different product sizes, and auto generate optimised stacking patterns to choose from; making them suitable for diverse industries and applications. This flexibility allows businesses to adapt to changing production requirements and market demands more effectively.
  • Integration with Production Lines: Automated palletisers can be seamlessly integrated with other production line equipment, such as conveyor systems, sorting machines, and packaging equipment. This integration enables a smooth flow of products from manufacturing to palletising to shipping, eliminating bottlenecks and optimising the overall production process.

Whilst these are some of the more common advantages and disadvantages of automated palletisers, it is important for businesses to evaluate their specific needs, production volumes, and budget constraints before deciding whether to invest in an automated palletising system.

You may find the following tools useful when analysing the advantages and disadvantages of automated palletising for your specific application:

You may also wish to complete a budget quote request on our project builder to get an understanding of what an automated palletising solution will cost for your specific application.  Simply fill in the details and we’ll get back to you with budget pricing within 24 hours. https://www.granta-automation.co.uk/project-builder

If you would like to discuss your specific application in more detail then feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.

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