Mechanical palletizer

Types of mechanical palletizers

A mechanical palletizer is a machine that arranges products on a pallet in order to facilitate product storage and shipment. Mechanical palletizers are an important part of any production line as they help automate the packaging process. There are three main types of mechanical palletizer: robot palletizers, mechanical palletizers, and dynamic or automatic pallet feeding systems.

• Robot palletizers:

Robot palletizers use a single robot to stack products in groups onto a pallet. Palletizing robots typically have multiple axes, allowing for more flexibility and control of product placement. They are also able to handle products of more varied shapes and sizes. One advantage of robot palletizers is that they have a smaller footprint in comparison to other types of palletizers. This is because the robot can perform many of the functions of the mechanical parts of the other, larger, machines. Palletizing robots can also be easily reprogrammed when the product changes, which makes them suitable for facilities that handle a wide variety of products.

• Mechanical palletizers:

Mechanical palletizers use a combination of mechanical arms, shuttles, and conveyors to stack products onto pallets. This system is more traditional and mostly used in places that deal with large quantities of products that are of uniform shape and size. One advantage of mechanical palletizers is that they can handle a large capacity and speed.

• Dynamic or automatic pallet feeding systems:

These systems are integrated with automatic pallet dispensers, which serve up empty pallets to the product as it is being fed to the area of stacking. This helps to make the entire process more continuous and lowers the number of manual parts administration workers have to do.

Another subtype of palletizers could be layer palletizers and top layer palletizers. In layer palletizers, products (usually large and heavy) are moved to pallets in layers, which is more convenient and efficient for the machine and the production line. Top layer palletizers, on the other hand, involve stacking only top layers of products on a pallet, which simplifies the process further and reduces the time taken to do so.

Mechanical palletizers are complex but essential machines that help to organize and stack the products that have been prepared for packaging and shipment. Knowing the differences in the types of mechanical palletizer can help buyers decide which one is suitable for their production line.

Specification and Maintenance

• Payload capacity: Mechanical palletizers can handle weights ranging from 50 to 100 kg. High-stacking capacity palletizers may handle weights of up to 500 kg or more.
• Palletizing speed: The speed capacity is typically 20 to 30 cycles/hour. High-speed mechanical palletizers may have a speed of 100 cycles/hour or more.
• Pallet dimensions: Mechanical palletizers are compatible with standard pallets sized 48''x 40'' and 60''x 60'' and non-standard pallets of various dimensions.
• Palletizing layers: Mechanical palletizers can handle multiple layers of products, ranging from 6 to 20 layers. High-stacking capacity machines may handle 20 to 40 layers.
• Control system: Mechanical palletizers are usually equipped with a control system that enables users to set palletizing patterns, speed, and other parameters. The control system may adopt PLC (Programmable Logic Controller) for flexible programming and automation.

Maintenance

• Regular cleaning: Clean the mechanical palletizer frequently to remove dust, debris, and residue. Pay particular attention to the important parts and conveyor belts to ensure smooth operation and prevent product contamination.
• Lubrication management: Implement a lubrication schedule for the palletizer according to the manufacturer's guidelines. Lubricate all parts, such as bearings, chains, and sliders, to reduce friction, ensure smooth operation, and extend the machine's lifespan.
• Periodic inspection: Conduct regular inspections of the mechanical palletizer. Check for vital parts, such as whether the fasteners are loose, the alignment is correct, and the state of the electrical components. Fix any problems or potential risks in a timely manner.
• Maintenance of pneumatic system: If the mechanical palletizer has a pneumatic system, it is necessary to maintain it too. Clean the air filters, inspect the pipelines, and check the operating conditions of valves and cylinders to ensure the normal functioning of the pneumatic system.
• Regular parameter adjustment: Adjust the parameters of the mechanical palletizer, such as speed, palletizing pattern, etc., according to changes in production requirements. Regularly test and fine-tune the machine for optimal performance and efficiency.

Industry scenarios of mechanical palletizers

• Packaging industry:

  In the packaging industry, mechanical palletizers play a crucial role in streamlining the process of stacking and organizing packaged products onto pallets. They efficiently handle various types of packages, such as cartons, boxes, shrink-wrapped bundles, and more.

• Food and beverage industry:

  Mechanical palletizers are widely used in the food and beverage industry to automate the stacking of finished products onto pallets for convenient packaging, distribution, and storage. They are commonly employed in facilities that produce items like bottled beverages, canned goods, dairy products, snacks, baked goods, and more.

• Pharmaceuticals and healthcare:

  In the pharmaceuticals and healthcare sector, mechanical palletizers are utilized to streamline the process of stacking products onto pallets for efficient packaging, storage, and distribution. They are particularly valuable in facilities that handle pharmaceuticals, medications, medical devices, diagnostic equipment, and other healthcare-related products.

• Electronics and automotive manufacturing:

  Mechanical palletizers find applications in electronics and automotive manufacturing industries for automated stacking of products onto pallets. In the electronics industry, they are used to stack items like circuit boards, components, sensors, and other electronic devices. Mechanical palletizers can also be employed in certain automotive manufacturing processes to stack automotive parts, accessories, and components.

• Construction and materials handling:

  In the construction industry, mechanical palletizers play a valuable role in automating the stacking of construction materials and products onto pallets. They help streamline the packaging and distribution process, improving efficiency and productivity.

• Logistics and distribution centers:

  In logistics and distribution centers, mechanical palletizers are valuable assets that automate the stacking of products onto pallets for efficient handling, storage, and shipping. These palletizers contribute to streamlining operations, enhancing productivity, and facilitating the smooth flow of goods within the distribution center.

How to Choose a Mechanical Palletizer

By considering the following parameters when selecting a mechanical palletizer, one can match their specific needs:

• Required Capacity: The amount of product that needs to be stacked per hour is one of the main determining factors in choosing a mechanical palletizer. Businesses with higher production rates should consider purchasing a palletizer that has the capacity to handle their product.
• Flexible: The ability of a mechanical palletizer to handle various product shapes and sizes is another important factor to consider. This includes being able to stack products in different configurations and also having adjustable stacking patterns.
• Conveyors and other machinery: The mechanical palletizer integration with other machines is another factor to consider when choosing the right palletizer. Mechanical palletizers usually work with product conveyors and also product dispensers. It is important to consider the integration of the mechanical palletizer and ensure a smooth workflow.
• Cost: Mechanical palletizers are usually costly, so clients need to ensure they are choosing a mechanical palletizer that is cost-effective and also meets their needs.
• Automation: The level of automation that a mechanical palletizer can provide is another factor that customers might consider when choosing the right mechanical palletizer. Customers may choose a mechanical palletizer that requires minimal manual work and, in turn, increases productivity.
• Maintenance and Service: When choosing a mechanical palletizer, it is necessary to consider the service and maintenance offered by the manufacturer. Some mechanical palletizers will need maintenance and occasional service to keep working optimally. In this case, it is important to choose manufacturers that offer maintenance and service support.
• Safety Features: Mechanical palletizers can be dangerous, and many accidents happen yearly. When choosing a mechanical palletizer, it is important to prioritize safety features like emergency stops, guarding, and also safety interlocks.
• Floor Space: Mechanical palletizers take up a lot of space. Therefore, it is important to consider how much floor area the mechanical palletizer occupies in the facility. Be sure to choose the mechanical palletizer that will easily fit into the available production space.

Q&A

Q1: What kind of product shapes can mechanical palletizers handle?

A1: Mechanical palletizers are commonly designed to handle regular-shaped products, such as rectangular boxes. Alternatively, they can also handle irregularly-shaped products through custom modifications, upon which the palletizer can use specialized grippers or forks to grasp and move products of various shapes.

Q2: What are the major components of mechanical palletizers?

A2: Mechanical palletizers typically include unitizers, product infeed systems, pallet delivery systems, pallet indexing systems, strapping or wrapping stations, and controls and sensors.

Q3: What are the advantages of mechanical palletizers?

A3: Mechanical palletizers offer a range of benefits. First, they can handle various products. They are efficient, increasing productivity. They also enhance safety and consistency and reduce labor costs.