How to Select the Right Palletizing System

Factors to consider when transitioning to an automated material handling process.

By: Brian Guzek, Contributor

The layouts for robotic palletizing systems are optimized to meet material handling requirements, and the facility footprint. Photo courtesy of Brenton, a ProMach Company.

There are many challenges customers need their packaging and material handling equipment to address. First and foremost is easy operation. This hinges on original equipment manufacturers (OEMs) designing equipment to be easy to operate, troubleshoot and maintain.

In addition, automation continues to influence the overall design of today’s packaging and material handling operations. Today, the entire end-of-line operation can be largely accomplished through automation. The result is often a safer end-of-line operation, with improved accuracy, optimized floor plans, faster production speeds and the flexibility to handle many different SKUs.

When selecting a palletizing system, it’s important to consider the primary challenges you need to address, and to establish an open line of communication with your original equipment manufacturer (OEM). Important questions you will need to discuss at the beginning of the project include:

• What are you looking to achieve in the short term and long-term?
• What is your industry and how would you describe your operating environment and workflow?
• How much floor space is available and are there any space constraints?
• What are the package formats, dimensions and weights of the materials to be palletized?
• What types of pallets, sizes and configurations will you need, and what is the target product weight each pallet will bear?
• How many product changeovers or SKUs do you anticipate?
• What is the budget and the timeline for this project?

A successful project requires a thorough understanding of all the variables that are involved in your material handling process. Having answers to these questions in the initial stages is critical because each one influences the other; if one of the answers to a question is unknown, it can sometimes dramatically change the scope of the project.

FACTORS TO CONSIDER WHEN SELECTING EQUIPMENT

Image courtesy of Brenton, a ProMach Company

The most important factor to consider when selecting pallet building equipment is ensuring it has the flexibility to grow with you in the future. Products and applications can change, and the materials you are palletizing today may be different three months from now. Your pallet building equipment needs the flexibility to evolve and adapt to your ever-changing needs. Here are some other factors to consider:

Safety features: Ensure that the equipment prioritizes safety. Look for features like safety guards, emergency stop buttons, and sensors that can detect and prevent accidents. Worker safety should be a top priority when selecting any machinery.

Ease of use and maintenance: Equipment that is easy to operate and maintain can save time and effort. Consider equipment with user-friendly interfaces, clear instructions, and accessible parts for maintenance and repairs. Additionally, look for equipment that is compatible with your existing infrastructure and can be integrated into your workflow seamlessly.

Reliability and durability: Pallet building equipment should be robust and able to withstand heavy use in an industrial environment. Look for equipment from reputable manufacturers known for producing reliable and durable machines. This helps minimize downtime and maintenance costs.

Flexibility and versatility: Look for equipment that can handle different pallet sizes, types, and configurations. The ability to adjust settings and adapt to various requirements is crucial, especially if you deal with a wide range of products or frequently change pallet specifications.

Automation and efficiency: Efficiency is essential in pallet building operations. Consider equipment that offers automation features such as robotic palletizers or automated stacking systems. These can significantly improve productivity and reduce labor costs.

Speed and throughput: Evaluate the speed and throughput capabilities of the equipment. Depending on your production requirements, you may need equipment that can build pallets quickly to meet demand without causing bottlenecks in your workflow.

Scalability and future expansion: If you anticipate business growth or changes in your pallet requirements, choose equipment that offers scalability. This allows you to expand your operations or adapt to new pallet sizes without the need for significant equipment changes or replacements.

Cost and return on investment: Evaluate the overall cost of the equipment, including purchase price, installation, training, maintenance, and operational expenses. Consider the return on investment (ROI) you can expect based on the equipment’s efficiency gains, labor savings, and increased productivity.

Service and support: Ensure that the equipment manufacturer provides reliable customer support, including technical assistance, spare parts availability, and maintenance services. Good after-sales support can help address issues promptly and keep your equipment running smoothly.

ADVANCES IN PALLETIZING TECHNOLOGY

Using robotics for palletizing eliminates the need for manual material handling, which greatly improves worker safety. The act of building a pallet by hand involves constant bending, twisting, reaching, and picking up cases, and injuries will inevitably occur. These safety risks contribute to a loss of production, as well as expensive worker’s compensation claims. Robotics remove this factor entirely from the equation.

Robotic automation helps mitigate worker safety concerns and ergonomics issues associated with manual pallet building. By taking over physically demanding or hazardous tasks, robots can protect workers from potential injuries. This leads to a safer working environment and reduces the risk of workplace accidents. Other areas where robotics is changing the way pallets are built include:

Accuracy: Robots can efficiently handle repetitive tasks such as picking and placing pallet components, precisely positioning them, and securing them with fasteners or adhesives. This automation improves production speed, accuracy, and consistency, leading to higher productivity and reduced labor costs.

Customization and flexibility: Robots enable greater customization and flexibility in pallet building. They can be programmed to adapt to various pallet sizes, designs, and configurations, allowing manufacturers to produce pallets tailored to specific customer requirements.

Efficient material handling: Robotics enable efficient material handling throughout the pallet building workflow. Robots can autonomously transport pallet components, manage inventory, and optimize material usage. By streamlining material flow and minimizing manual handling, robots enhance operational efficiency and reduce material waste.

Scalability: Robotic systems can be easily scaled up or down to match production demands. Manufacturers can deploy additional robots or reconfigure existing ones to increase throughput during peak periods. This scalability allows for better resource utilization, improved production planning, and greater responsiveness to market fluctuations.

Most palletizing applications can see great benefits from the addition of robotics. One of the biggest advantages of robotics is the flexibility they bring to palletizing. Being able to pick and place different case sizes and multiple SKUs gives them the flexibility to handle a wide variety of applications with a single robot. Additionally, different end of arm tooling such as clamps, vacuum cups, fingers and other designs give robots further ability to pick and place a diverse range of cases and product sizes.

THE IMPACT OF ROBOTIC PALLETIZING

The bottom line is that robotic palletizing improves workplace safety by eliminating the need for operators to manually place cases on pallets. This also helps from a labor standpoint. Trying to hire and retain staff to manually build pallets all day is extremely difficult. Robots do not call in sick; they reliably operate around the clock. In fact, a well-designed robotic palletizer can be operated by just one person, maximizing end-of-line efficiencies, increasing palletizing speeds and providing flexibility to create customer-specific pack and pallet patterns. WMHS

Brian Guzek (Brian.Guzek@promachbuilt.com) is the regional sales manager with Brenton, a ProMach brand. Brenton is a global leader in designing and manufacturing integrated end of line case packaging systems and machines, specializing in case packing and palletizing using both robotics and other automation. Learn more at www.brentonengineering.com.