High speed palletizer

Types of high-speed palletizer

A high-speed palletizer is an automatic device that stacks products or packages efficiently at a high rate onto a pallet. It is an integral part of the manufacturing or packaging line for products. There are numerous types of high-speed palletizers, with varying speeds, sizes, and levels of automation.

• Robotic palletizers

  Robotic palletizers use an industrial robotic arm to identify, orient, and place products onto a pallet. They are well-suited for handling products with varying shapes and sizes. This includes cases, trays, and bundles. One of the biggest benefits of robotic palletizers is their flexibility. This means that they can easily be reprogrammed to handle different products or change pallet patterns. They also have the capacity to take on additional tasks. These could include product inspection, sorting, or packaging. This is achievable without needing extra equipment. Robotic palletizers are also easy to maintain and have a lower level of required maintenance.

• Hybrid palletizers

  Hybrid palletizers combine the strengths of robotic and traditional palletizers. They take on a vision-guided robotic picking system that is integrated with a conventional palletizing unit. The unit first picks individual products from a conveyor system after which the conventional palletizing unit handles the remaining products. Hybrid palletizers boast improved speed and flexibility when handling multiple products. They also offer more configuration and pattern options than traditional palletizers alone.

• High-level palletizer

  A high-speed, high-level palletizer stacks individual products or groups of products onto pallets at high speeds. Products enter the system from the top, and the pallets are removed from the bottom. This allows for easy integration. It also supports in-line or right-angle product entry. High-level palletizers are usually faster than low-level palletizers, typically handling between 20 to 200 pallets per hour. They suit facilities with limited floor space who must quickly process and ship products.

• Layering palletizer

  Layering palletizers are a type of automated machine that stack multiple layers on a pallet before going to the next layer. They are ideal for handling cases, cartons, and bags. Layering palletizers can achieve high speeds and handle large volumes of products, making them suitable for high-production environments.

Specifications and Maintenance of High Speed Palletizers

Specifications

The following list describes important specifications for high-speed palletizers.

• Throughput: This term describes the number of units that a palletizer can pallet per hour. High-speed palletizers typically have throughput rates ranging from 60 to 300+ pallets per hour, depending on the machine model and configuration.
• Palletizing Speed: The speed at which a high-speed palletizer constructs pallets or layers of products. This speed determines how quickly products are sorted, stacked, and packed onto pallets. High-speed palletizers offer fast palletizing speeds. (e.g., 2000-4000pcs/hr)
• Pallet.Size: This term refers to the dimensions of the pallets used for packaging and storage. High-speed palletizers can handle various pallet sizes to accommodate different products and organizational needs. For example, 120 x 100 cm 48 x 42 inch, etc.
• Product.No: This term refers to the various products that high-speed palletizers are designed to handle and palletize. Different models and configurations of high-speed palletizers may be capable of accommodating distinct product types, such as boxes, cartons, bottles, cans, and other container variations.
• Palletizing Pattern: A method for arranging products on a pallet for storage or distribution. High-speed palletizers can handle different palletizing patterns according to the needs of the organization. For instance, layer-by-layer stacking, interlocking, and random stacking may be employed.
• Automation & Control: High-speed palletizers have automated systems and control techniques for efficient and accurate pallialization. These may include computerized control systems, sensory recognition, robotic manipulation, and different automation levels.

Maintenance

• Regular inspection

  Regularly inspect the palletization system to look for possible issues such as loose parts, abnormal wear, misalignment, etc. Timely adjust, tighten, or repair these problems to ensure stable operation and reliability.

• Lubrication

  Perform lubrication for moving parts, such as bearings, gears, etc., according to high-speed palletizer maintenance manuals. Ensure proper application of lubricant to reduce friction and wear, and regularly check and maintain the lubricant's quality and levels.

• Cleaning

  Periodically clean the palletizing machine and its accessories to remove dust, debris, etc. This step helps prevent blockages and malfunctions, ensuring stability and accuracy in high-speed palletizing operations.

Scenarios

High-speed palletizers are used in various industries that produce large quantities of products and require efficient stacking and packaging. Here are some of their common usage scenarios:

• Food and Beverage

  High-speed palletizers are widely used in the food and beverage industry to stack containers, cartons, and trays of food and drinks onto pallets for efficient packaging and distribution. They can handle different types of packaging, such as cartons, bottles, cans, and jars, and are designed to meet strict hygiene and food safety standards.

• Industrial Manufacturing

  In industrial manufacturing, high-speed palletizers are used to stack boxes, containers, and other products onto pallets for packaging and shipping. They can handle various materials, such as metal, plastic, and wood, and are designed to increase productivity and reduce labor costs in manufacturing facilities.

• Automotive

  High-speed palletizers are used in the automotive industry to stack automotive parts and components, such as engines, transmissions, and interior parts, onto pallets for assembly and distribution. They are an essential part of the automotive production process, helping to streamline material handling and improve workflow.

• Electronics

  In the electronics industry, high-speed palletizers are used to stack electronic products, such as smartphones, tablets, computers, and other devices, onto pallets for packaging and shipping. They are designed to handle delicate and high-value products with precision and accuracy.

• Pharmaceuticals

  High-speed palletizers are used in the pharmaceutical industry to stack pharmaceutical products, such as medications, vitamins, and other health products, onto pallets for packaging and distribution. They are designed to meet strict regulatory requirements and ensure the safety and quality of pharmaceutical products.

• Glass industry

  In the glass industry, high-speed palletizers are used to stack glass products, such as bottles, containers, and flat glass sheets, onto pallets for packaging and shipping. They are designed to handle fragile and easily breakable materials with precision and care.

• Consumer Goods

  High-speed palletizers are used in the consumer goods industry to stack products, such as personal care items, cleaning products, pharmaceuticals, and other consumer products, onto pallets for packaging and distribution. They help to improve efficiency and reduce labor costs in the consumer goods manufacturing process.

Choose the suitable high-speed palletizer

High-speed palletizers are vital pieces of machinery in warehouses, construction sites, and logistics services. Choosing the suitable high-speed palletizers can determine workflow productivity. Here are some factors to consider when selecting high-speed palletizers:

• Speed: This is, without doubt, the most important factor when choosing a high-speed palletizer. Businesses should determine how fast they want their products to be packed. The speed of a high-speed palletizer can influence the efficiency of a production line. Consider finding a high-speed palletizer with adjustable settings to accommodate different pace requirements.
• Flexibility: High-speed palletizers come in different tiers. Some are more flexible than others regarding handling different product types. Consider the product's size, shape, and weight. Ensure the high-speed palletizer can handle the product with minimal adjustment. This will reduce downtime.
• Integration: Consider finding a high-speed palletizer that can seamlessly integrate with existing equipment and software. The palletizer should have compatible input/output interfaces and communication protocols. It should also have similar control systems to minimize disruptions during installation.
• Cost: High-speed palletizers come at a price range depending on factors like speed, flexibility, and capacity. Businesses should consider initial purchase costs, installation expenses, and ongoing maintenance costs. More importantly, they should look into potential ROI and productivity gains when determining a suitable high-speed palletizer.
• Safety features: High-speed palletizers pose many safety risks due to their size, weight, and speed. When choosing a high-speed palletizer, one should look into the safety features it offers. This includes guards, emergency stop buttons, and sensor systems. Safety features should also include operator-friendly controls and ergonomic design.
• Reputation: Manufacturers and suppliers of high-speed palletizers have different reputations. Research into the supplier's reputation, the review of their service, and the support they offer. Choose a high-speed palletizer from a manufacturer with proven reliability and customer support.

High speed palletizer FAQ

Q1: What is the difference between a high-speed palletizer and a low-speed one?

A1: The main difference is the speed. High-speed palletizers manage product throughput of more than 50 pallets per hour, while low-speed palletizers handle less than that. High-speed palletizers also tend to have more advanced automation.

Q2: Can high-speed palletizers accommodate mixed loads and different pallet patterns?

A2: Yes. High-speed palletizers are configurable to handle mixed loads and various pallet patterns. They can also switch between different product combinations with minimal downtime.

Q3: Are high-speed palletizers safe to operate?

A3: Yes. Modern high-speed palletizers have safety features such as emergency stop buttons, safety interlocks, and guarding to protect operators. Appropriate risk assessments and safety protocols are necessary, though.

Q4: Can high-speed palletizers be integrated with existing production lines?

A4: Yes. High-speed palletizers are designed for integration with other processing components, such as high-speed conveyor systems and automated sorting mechanisms. Customization and engineering are needed for the integration.