Palletizing

Palletizing

Robotics is one of the most flexible and cost effective packaging solutions for today’s competitive market.  State-of-the-art precision, reduced work related injuries, and a high return on investment make robotic packaging systems an increasing choice for solving the challenge of processing finished goods efficiently.

Description

Robotics is one of the most flexible and cost effective packaging solutions for today’s competitive market.  State-of-the-art precision, reduced work related injuries, and a high return on investment make robotic packaging systems an increasing choice for solving the challenge of processing finished goods efficiently.

Robotic Dual Palletizing of Boxes

The robotic palletizing cell can load two different box sizes onto separate pallets simultaneously.  The robot automatically picks up the box from the end one of two conveyors.  RFID technology is used to communicate in real-time with the robot to complete the palletizing sequence.  The robot with presents the box to a print and apply label applicator where labels with product specific information are applied to the box. Next, the robot stacks the box on the appropriate pallet in a programed pattern.  The robot also places slip sheets on each pallet and between box layers for stability.  When a pallet is complete, an operator can disable the palletizing cell momentarily to remove the finished pallet without stopping the rest of the packaging line.  Once an empty pallet has been placed and the cell enabled, palletizing can continue.

Robotic Palletizing of Boxes

The robot will remove boxed rolls from an accumulation conveyor and place them on the pallet.  The robot stacks the boxes on the pallet in a programed pattern.  The robot also places slip sheets on each pallet and between box layers for stability.  When the pallet is complete it will advance to the end of the powered conveyor.

The pallet will move through a muting safety light curtain.  This section is one pallet deep outside the guard to allow operators to remove it with a forklift.  Additional pallets are dispensed from an automatic pallet dispenser.

Robotic Palletizing of Rolls

Custom “End of Arm Tooling” for this robot is designed and programmed to provide two functions; roll handling and slip sheet handling.

When a set of finished rolls reach the end of the conveyor, the robot picks up the rolls, turns them upright and places them onto the pallet in a pre-determined order.  The robot can be programmed to automatically palletize finished rolls in a variety of stacking patterns.

After each pallet is complete, the prior pallet will move through a muting light curtain and to an accumulation area.  This section is one pallet deep outside of the perimeter guarding to allow operators to remove the pallet without disrupting operation.

Additional pallets are dispensed from an automatic pallet dispenser.  Once in position, the robot places a cardboard sheet onto the pallet and the process repeats.

Robotic Palletizing of Extra Large Rolls

The versatility of this robot will stack and palletize large rolls with widths ranging from 3 to 36 inches, diameters ranging from 8 to 18 inches and weights ranging from 17 to 200 pounds.

The large diameter rolls travel along a zero back pressure conveyor and are staged at the robot pick point.

When processing narrow width rolls, the custom “End of Arm Tooling” utilizes a vacuum pad gripper that makes contact with the top face of the roll.  The vacuum is initiated and the roll is picked up and placed on the pallet in a programed pattern.  The robot also places slip sheets on the pallet and between roll layers for stability and to maintain roll quality.  When a pallet is complete it will advance to one of three full pallet staging positions.  The third staging position will allow an operator to remove it with a forklift.

When processing wider width rolls, the robot will the end of arm tooling utilizes a roll clamping device to pick and place the rolls.  The robot will continue to pick and place rolls until the pallet is full.  Additional pallets are placed manually at the leading end of the palletizing conveyor and indexed automatically into the palletizing cell.

Palletizing Bulk Rolls   

This automated packaging line palletizes bulk rolls of plotter and ink jet paper with finished roll lengths of 500 and 600 feet.   A large cardboard tub is fastened to a pallet prior to packaging.  A series of pneumatic push bars create a programmed layer pattern with the finished rolls.  Once a layer is complete, the forming table moves into the box and transfers the rolls.  The tub and pallet are turned on their side as the layers of finished rolls are transferred into the tub.  Once the last layer is loaded, an elevator lowers the tub.  A conveyor system moves the tub into an up-ender and turned upright.  Once the filled tub reaches the end of the exit conveyor, the operator can remove it from the system with a forklift.

A similar system is also offered that utilizes an elevator lift to raise and lower the transfer plate to the layer pattern for the tub.  This allows the tub and pallet to remain in one position during the loading process.  This palletizing system also offered an option to palletize cases.

Palletizing Boxes

Prior to palletizing the boxes, this automatic packaging line individually inserted 2 rolls into each box.

The pallet is turned on its side as the boxes are transferred onto the pallet.  A series of pneumatic push bars create a programmed layer pattern with the boxes.  Once a layer is complete, the forming table moves the boxes and transfers them onto the pallet.    Once the last layer is loaded, the up-ender turns the loaded pallet upright.  An operator can remove it from the system with a forklift.   This palletizing system also offered an option to palletize bulk rolls.

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