Palletiser

Posted on May 15, 2023 by Granta

A palletiser is a system that stacks products onto pallets. There are many different types of palletiser on the market but the most common and versatile for different types of application is a robotic palletiser.

How do they work?

All palletisers are equipped with a gripper for picking product and an actuator or robotic arm for moving the gripper and product. An infeed conveyor feeds product into the palletiser and then products are picked by palletiser from the infeed conveyor and stacked onto pallets automatically. The pallets can be automatically fed into the system with a pallet feeder or they can be manually fed into the system with a forklift or pallet truck. Finished stacked pallets can be manually removed from the system, or automatically fed out of the system on conveyors. Automated pallet wrappers can also be included if required.

Example grippers

Example grippers used on a palletiser include:

  • Foam pad gripper – a foam pad gripper lifts product using vacuum
  • Bag gripper – a bag gripper has tines that close around the product.
  • Underneath gripper – an underneath gripper had a plate or tine that the product is slid onto and then clamped
  • Parallel Gripper – a parallel uses two plate to grip either side of the product.

More information on griper types and their suitability for different products is available here.

Application examples

There are many different applications in which a palletiser is used. Some of the more common applications are listed here:

Software

All palletiser systems will have some form of software controlling them, there is a wide range of software available from hard coded robot paths and stack patterns where every move is individually programmed by a skilled robot programmer, through to fully automatic software that any person that is familiar with computers can easily use to automatically generate stack patterns in less than 5 minutes. One of the fastest and most flexible software options on the market is the GA15 Palletising software.

Hardware

There is a wide variety of hardware needed in palletising cells such as conveyors, robots, actuators, grippers, control gear and much more. Some of the better palletiser systems on the market have modular systems that enable easy re-deployment and re-configuration of the system layout, along with very fast install. The GA15 Palletiser has a patented modular system that enables very fast install, modification, and accommodates almost any layout requirements, it is known as the Lego of palletisers.

Some key factors to consider when installing a palletiser include:

  • Palletiser speeds required
  • Product type and structural rigidity
  • Size and weight of products
  • Stack patterns
  • Integration requirements with upstream equipment
  • Types of pallets
  • Layout and available space requirements
  • Scanning and barcode reading for sorting products
  • Pallet wrapping requirements

More information on factors that need to be considered when installing a palletiser is available here.

Planning a palletiser install?

There are a lot of factors to consider to ensure you achieve successful palletiser installation, see below for a link to a guide to palletiser installations and downloadable template URS.  https://www.granta-automation.co.uk/news/palletiser-buying-guide/

Support

Having good support is a key to a successful palletiser install, both for ongoing training of new users and quick fault recovery. A good support contract will include 3 site maintenance visits per year and remote support availability.

Further information on palletisers

For further information on palletisers see https://www.granta-automation.co.uk/types-of-automation/robotic-palletising . You may also wish to download our free robotic automation resource pack https://www.granta-automation.co.uk/resources

If you would like to discuss this in more detail, or would like further information on the Granta GA15 Palletising system, then please do get in touch on 01223 499488 or helpline@granta-automation.co.uk. 

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Palletiser Buying Guide

Posted on May 8, 2023 by Granta

There are many different automated palletising systems available on the market, so we have put together a few key points that you should consider before investing. This will ensure that your investment will meet your current needs as well as being flexible enough to cope with any future changes in your requirements.

Key Benefits of An Automated Palletising System

1. Production Increase

Most companies typically experience a 40%+ production increase following the installation of an automated palletising system.  There are several reasons for this level of increase:

  • An automated system does not take holidays or breaks, so you production process does not need to stop
  • As the system is automated it forces a takt time. This means that the production process up the line has to keep to this takt time to ensure the palletiser is running at optimum speeds.
  • The system will run 24/7, working longer hours than an employee palletising by hand.
  • An automated system will achieve faster palletising speeds as there is no risk of the system stopping palletising due to distractions or RSI issues.

2. Fast Payback

The payback time on an automated system will be specific to your applications but it is usually very quick. Typically, as a rule of thumb, if you have the equivalent of one person employed full time for palletising, there is payback in less than 2 years.

3. Reduction in Health & Safety Claims

An automated palletising system completely removes the risk of repetitive strain injuries occurring, and therefore removes all of the associated costs that go along with RSI Health & Safety claims.

4. Other benefits

There are many other benefits associated with an automated palletising system, but some of the more commonly recognised benefits include; impressed customers, reduction in pallet stacking errors, improve stack quality, less transit damage, improved staff morale.

Return On Investment

The payback time for an automated palletising system is usually very quick, as not only do you remove the manual labour element and associated costs, but production can also continue to run throughout break times, etc.  This enables you to improve your production speed and throughput capacity, enabling you to product more product in less time.

To help you calculate the ROI for your project, we have created a free, downloadable robotics and automation resource pack www.granta-automation.co.uk/freepack. This pack includes an automation project payback calculator to help you determine your predicted return on investment based on production rates, shift times, HR costs, downtime, etc. It also includes an intangible benefits calculator as these are also something that need to be considered when working out your predicted return on investment as they can have a significant effect on the payback time of your project.

Things To Consider When Buying A Palletiser

1. Staff Training and Ease of Use

How easy is the palletising system to use? Can it quickly be reprogrammed to palletise different bag or box sizes? Can your staff reprogram it themselves? With some conventional palletising systems it can be very difficult to change the stacking pattern or bag placing positions without support from a specialist programmer. Therefore, it is important to ensure that the system you choose has easy programming software as this will enable your staff to reprogram the palletiser quickly and easily. This saves you the cost of having to call out an expensive robot programmer to reprogram the system when you need to change a stack pattern or bag size. It is also important to choose a system that has automatic stack generation software so that you can simply choose which stacking pattern you wish to use without having to spend time planning. Having a system with easy programming software will also ensure that your palletising system is future proof against any changes of product size or pallet type.

It is also important to ensure that your staff will receive training as part of the palletiser installation process.  A good training process will give your staff the needed skills to operate the palletising system in the most efficient and effective way.

2. Futureproof Throughput Capacity

What throughput do you need to achieve currently? What throughput are you looking to achieve in the future? Not only do you need to be sure that the system can meet your current throughput requirements, but it is also important to ensure that it has the necessary capacity to enable you to expand your sales and increase your throughput in the future. The last thing you want is to increase your sales only to find your palletiser has become a bottleneck in your production process! Spend time to think about where your business is heading in the future and ensure you invest in a system that will meet your future demands, or is easily scalable to meet them.

3. Stack Neatness

Neatly stacked pallets are key to your product reaching its final destination in the best condition. They also make for safer storage, and easier container and lorry loading. With several different methods of automated pallet stacking available, it is important that you choose a method that creates the best stack for your product. There are many factors that affect how bags will stack best such as how full the bag is, what type of product is in the bag, and how free flowing the material is within the bag. Several systems are available for shaping and flattening bags to ensure that they stack in the neatest possible way. Running a trial of your product on a palletising system before you commit to the capital expenditure is a very good way to determine what the best method is for palletising your product neatly.

4. Easy to Move/Re-site

Ensure that the system you choose can be easily moved. As your processes evolve over time, the last thing you want is to end up with a palletiser stuck in the wrong corner! There are modular palletising systems available; which means they can be quickly and easily re-situated and reconfigured to a different layout should the need arise. The modularity of these systems also allows you to adapt the palletising process over time by adding further processes at a later date such as pallet shrink wrapping, slip sheet feeding, automated pallet feeding, labelling etc. 

Downloadable Palletiser URS Template

To help you with choosing and specifying an automated palletising system we have created a downloadable Palletiser URS template.  This includes all of the key specifications that need to be considered when specifying a automated palletising system, and helps to ensure that the system will not only meet your current needs, but also your future requirements as well.

As you can see, when chosen wisely, an automated palletising system will not only provide the immediate benefits of increased reliability and throughput, but will also service your future requirements. With changing market demands and the ever-quickening pace of technology, it is important to ensure that the equipment you choose to invest in is flexible and adaptable enough to cope with these changes without the need for further significant investment.

One of the most adaptable and flexible palletising systems on the market is the Granta GA15 palletising system. It is fast and easy to program without the need for specialist programming skills. The easy programming software also includes automatic stack generation for an infinite variety of products, pallets and stack configurations. Having input the bag or box size you are palletising the optimum stack pattern is shown along with a variety of other stack patterns. All you have to do is simply select the stack pattern you require using the touch screen.

As the Granta GA15 palletising system is a modular system, it can also be simply and quickly reconfigured should your production requirements change. The modularity of the system also results in short lead times and a quick install time.

If you would like to discuss this guide in more detail, or would like further information on the Granta GA15 Palletising system, then please do get in touch on 01223 499488 or helpline@granta-automation.co.uk. 

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Can Pallets Be Depalletised Automatically?

Posted on April 19, 2023 by Granta

Almost any type of product can be automatically depalletised, and the best method will vary depending on the type of product that is being depalletised and the speeds required. Depalletising of boxes or bags will often be done by a robot picking and placing the items one at a time, but for high-speed applications, such as depalletising bottles onto a production line, the product will usually be picked and placed as a complete layer to meet the speeds required.

There are many different reasons why a pallet may need to be depalletised, and some of the most common reasons are listed below:

  • Cross stacking product from Euro pallets to UK standard pallets to fit the UK distribution network and pallet storage system.
  • Depalletising items such as empty bottles or containers onto a production line ready for filling.
  • Depalletising boxes or bags off a pallet onto a conveyor ready for loading into a container for shipping.
  • Depalletising and repalletising of boxes or bags to get the correct quantity or stack pattern onto a pallet.

Cross stacking of bags or boxes from one pallet to another will typically be done by a robotic depalletising system and the system will usually be designed to suit your specific application and speeds.  The robotic arm will pick and place one item at a time and compensator tools may be used by the robot to allow for product variations. An angled alignment frame or conveyor system may also be needed to enable the product to be accurately re-positioned onto the new pallet.

Where product is being depalletised onto a production line or onto a conveyor for loading a container, the speeds required will determine the pick and place method. For slower speed applications items will be picked and placed individually, whereas for high-speed applications a complete layer, or row can be picked and placed onto the production line. Once the product is on the conveyor, it will then be orientated and separated as required by the production process.

Typically, a depalletising system will be built to suit your exact requirements, and can be designed to include pallet wrapping and labelling if needed.

Some of the key benefits to automatically depalletising product include:

  1. Improved efficiency: An automated depalletising system is more efficient than manually depalletising as it will not need to stop for breaks, holidays, etc., enabling you to run your depalletising process 24/7 if required.
  2. Improved safety: An automated system will remove the need for manual handing of product, and therefore reduce the risk of repetitive strain injuries occurring.
  3. Flexibility: Some automated depalletising systems have software that can be reprogrammed by your staff which gives you flexibility and enables you to use the system to depalletise a wide variety of products on the one system.

If you would like to discuss your depalletising application, feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk. 

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Can You Lease A Palletiser?

Posted on April 12, 2023 by Granta

Yes you can, is the answer to this question!  Leasing is a very efficient way of purchasing a palletising system as it helps cashflow by removing the need for a large capital outlay at the time of purchase. It also removes the need for CapEx approval in the buying process.

With leasing you pay nothing until the palletiser is installed, and start making savings over and above the lease payments from the day the palletiser is installed.

To give you an example; over the last few projects, with a 3 year lease scheme, our customers would make an average production cost saving of £63,063.60 per year after making the lease payments.

These savings do not include the value of:

  • Production increase – which with a palletiser is typically at least 15%, and more commonly around 40%.
  • Reduced Health & Safety claims.
  • Reduced HR time and cost.
  • Boosted staff morale.

At the end of the lease period the palletiser becomes yours for a small nominal fee of 1%.

Click here to download our Automation Payback ROI Calculator with Leasing Options and find out what savings you could be making. This calculator covers the many different factors that need to be considered when comparing your existing processes with an automated system.

If you would like to discuss leasing a palletising system feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk. 

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Automated Product Sorting and Palletising

Posted on April 5, 2023 by Granta

It is a common requirement both at distribution centers, and on the output of production lines, to need to sort products and palletise them ready for dispatch. Some common requirements include:

  • Sorting and palletising into van/delivery routes
  • Sorting and palletising by barcode
  • Sorting and palletising into product types
  • Sorting and palletising by product weight
  • Sorting and palletising by size
  • Sorting and palletising by customer order number

Key information required for product sorting

Almost any product can be sorted and palletised including boxes, totes, trays, bags and much more, but there is some key information that is required to be considered first:

  • What products need sorting?
  • Are they consistent, or a range of different types and sizes?
  • What speeds do they need sorting at?
  • What is the input to the system; is it multiple lines that need combining and sorting, or one line that needs splitting and sorting?
  • How many sorted output pallets need to be stacked at one time?

What is the method for detection for how products should be sorted?

There are several methods by which products can be sorted, some examples are below:

  • Barcode – Barcode readers detect the barcode and sort according to data from a database or pre-set program.
  • QR code – QR code readers detect the code and sort according to data from a database or pre-set program.
  • Size measurement – In-line 3D measuring systems can detect product sizes and sort accordingly.
  • Weight measurement – Scales in line with the input to the system can weigh products and then sort them accordingly.
  • Character recognition off a label – Vision systems can detect the code and sort according to data from a database or pre-set program.

Sorting and palletising methods

Products can be sorted in multiple ways, typically you have products entering the system on a conveyor combined together and they are detected and allocated for sorting to the correct pallet by one of the above sorting methods. Once this allocation is made the products need to be sorted physically and palletised. The key methods for sorting and palletising are as follows:

  • Sorting with the robotic palletiser
  • Sorting with conveyors then palletising
  • Sorting with a buffering system

These are explained in more detail below.

Sorting with a robotic palletiser

Sorting with a robotic palletiser is where the input conveyor to the palletiser has mixed products that need sorting. The palletiser has multiple palletising locations and stacks the products onto the relevant pallet.

For example, the image below shows two sorting Palletisers both stacking to six output pallets; so overall the system is sorting and palletising products between twelve different pallets.

Sorting with conveyors then palletising

Sorting with conveyors is where products are diverted off into different lanes going to the palletiser, this means products are already sorted and combined on input lanes into the palletisers. This is more common where there is high production throughput and products need to be pre-sorted before the palletiser to enable row grip (multi picking products to improve production speeds).

Sorting with a buffering system

Sorting with a buffering system is often effective where there are many different output pallets required but overall production is not all that fast. With this type of system the products are all sorted and stored temporarily in elevated storage systems into batches of product ready to be palletised once a whole pallet worth of product is ready. Like this you can often have just one or two robots serving a large sorting requirement.

Database integration

Often to sort most effectively the barcode or QR code information needs to be looked up on an existing customer database system. To do this the palletising system is integrated using bespoke coding that links up with client databases or imports excel / CSV outputs from client databases. The system then uses this information to determine the sort method and palletise.

If needed, feedback to the database can be given from the palletiser and sorting system to show any extra information from the product; giving real time information on where products are in the system and where products have been stacked. For example; often a barcode reader in the final palletising cell is used to verify the products have been palletised and is used as the method of scanning the product out of the system for delivery.

Conclusion

There are multiple methods of sorting and palletising and often these methods are combined along with database integration to achieve the best outcome. For help with your specific sorting and palletising requirements contact us on 01223 499488 or helpline@granta-automation.co.uk. 

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Bag Palletiser

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Crate Palletiser

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Granta GA15 Compact Palletiser Cell

Posted on February 23, 2023 by Granta

The standard layout of a Granta GA15 compact palletising cell is approximately 4 meters x 1.6 meters in size, but this can vary depending on your application. The main advantage of this cell is the fact that it is very compact, whilst still having the benefits and payloads of an industrial robot palletising system.

Key features of the compact palletising cell include:

  • Pallet trucks can be used for pallet change as well as fork lift trucks. This is very useful where space is tight and pallet trucks need to be used as there is not room for a fork lift truck.
  • The system can be used on high speed lines and can include row gripping if required. Many compact systems are not able to handle high speeds and volumes of product as they are not able for the required cycle times. This systems has the benefit of being compact as well as able to handle quick cycle times.
  • 120 kg robot payload which allows the system to palletised heavy boxes and bags despite it’s compactness.
  • Entry to the system can be via a physical gate or light curtain

Points to be aware of with a compact palletising cell are:

  • The system will stop whilst pallets are removed and changed over. This does not usually present a problem unless you are running a very high speed line and do not have the necessary buffering space.
  • Slip sheets and auto pallet feeding can be added to the system but this will increase the cell size.

Compact palletising cells are typically used where there is very little floor area available, and the budget is tight. The system is very compact in size, but is more versatile than a cobot palletising system as it has the payloads and speeds of an industrial robot palletising system.

If you would like to discuss the best palletising system for your specific application, and the speeds/cycles times that can be achieved, feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk. 

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Bag Palletiser

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Barrel Palletiser

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Box Palletiser

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Crate Palletiser

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Tray Palletiser

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What Palletising Speeds Can Be Achieved with Different Grippers?

Posted on February 9, 2023 by Granta

Depending on the product and gripper size, robot grippers can pick many products at a time speeding up the throughput of the palletiser by picking and placing multiple products at a time. The speed that the 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.

The table below shows typical speeds that can be achieved with different grippers. These are approximate average speeds and are very dependant on application, please contact us to get the actual likely speeds for your application.

If you would like to discuss the best gripper for your specific application, and the speeds that can be achieved, feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk. 

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How To Select the Correct Gripper Type For Your Palletiser

Posted on January 31, 2023 by Granta

There are many different gripper types available, and the type of gripper required will depend on the product and application.

The table below lists some of the standard products in the industry along with an indication of the best gripper technology to use. Obviously, every application is unique so please contact us to get an accurate assessment of the gripper type required.

If you would like to discuss the best gripper for your specific applications, feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk. 

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Posted in Bag Palletiser, Box Palletiser, Container Destuffing, Container Destuffing Palletising, Container Unloading Palletising, GA15 Palletiser, Palletiser - Granta GA15 Palletiser System, Palletising, Robotic Palletising | Tagged , | Comments Off on How To Select the Correct Gripper Type For Your Palletiser

What Are The Key Benefits Of An Automated Palletising System?

Posted on January 26, 2023 by Granta

There are many different benefits of an automated palletising system, and the benefits to your company will be directly related to your own specific situation. However, there are some benefits that are common to virtually every automated palletiser installation and these are outlined below.

  1. Production Increase

Following installation of an automated palletising system, most companies typically experience a +40% production increase.  This is usually due the following factors:

  • An automated system does not take holidays or breaks, so there is no need for your palletising or production process to stop.
  • As the palletiser is reliable and consistent in its output, there is then a forced takt time. This means that the production process further up the line has to keep to this takt time to keep the palletiser running at optimum speeds.
  • An automated system will be able to work longer hours than an employee palletising by hand.  The system will work shift after shift, and can also work 24/7 if required.
  • Faster palletising speeds can be achieved with an automated system.  This is partly due to the fact that the system won’t stop or get distracted, along with the fact that the RSI risk has been removed.
  1. Fast Payback

Payback on an automated palletising system is usually very very quick if you are currently palletising by hand. By the time you have factored in labour cost savings, value of the increased production output, and the savings in HR cost and RSI risks, payback time is often less than one year.

  1. Reduction in Health & Safety Claims

Health and safety risks are usually high when you are palletising by hand due to the large amounts of manual labour required.  However, with an automated palletising system these risks and the associated costs are completely removed, thereby reducing your risk of Health & Safety claims from palletising to zero.

  1. Other Benefits

There are many other benefits of an automated palletising system, however some of the additional key benefits that our customers have found include:

  • Impressed customers. When your customers see a robot palletising in your factory, they can’t help but be impressed with your technologically advanced processes.  This in turn helps to build and improve customer relationships and trust as they can see that you’re using the best and most cost-effective methods of producing the products you’re selling to them.
  • Reduction in errors and improved stack quality.  An automated palletising system will reliably pick and place product onto the pallet in exactly the right position.  This removes the risk of transit damage and pallet slippages being caused by product being placed incorrectly on the pallet. It also removes the associated costs of having to replace product that has been damaged in transit.
  • Boosts staff morale.  An automated palletising system typically boosts staff morale.  This is often due to the fact that staff no longer have to perform the repetitive task of stacking pallets by hand, and are enjoying their new role within the company.  Staff also enjoy the feeling of achievement they get by learning how to run and reprogram the palletising system.

Whilst these are some of the benefits of installing an automated palletising system, this is by no means an exhaustive list.  Each installation will have its own merits and benefits depending on the current method of palletising and the type of automated system that is installed.

If you would like to know more about the GA15 palletising system, feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk. 

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Bag Palletiser

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Crate Palletiser

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Tray Palletiser

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Can A Palletiser Stack Boxes And Crates With Open Tops?

Posted on December 7, 2022 by Granta

Open top boxes and crates can indeed be automatically palletised as shown in the video below!

The typical method for automatically palletising open top boxes or crates is for the product to come off the production line conveyor onto an underneath pick station. The product is then pushed off the pick station onto the tines of the underneath gripper head.  Once on the underneath gripper tines, a clamp then clamps the top edge of the box or crate to hold it securely as the item is moved across to the pallet stack.  Once the product is in the correct position on the pallet stack, the gripper will release the top clamp and slide the product onto the pallet stack.

If you would like to know more about the different types of product that can be palletised and the methods used, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will also be very happy to arrange a free trial of your product on a palletiser if you require this.

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