The Advantages of Robotic Palletizers vs. Layer Palletizers - Sponsored Whitepaper

The Advantages of Robotic Palletizers Compared To Conventional Layer Palletizers

Robotic Pallet Cell with Integrated Pallet Flow-Through Conveyor

Layout of Robotic Pallet Cell with Integrated Pallet Flow-Through Conveyor

Introduction Palletizing has evolved since the days when manual stacking presented the only solution. Today low infeed and high infeed layer palletizers can be specified to automate the process, reducing back injuries and increasing speed and efficiency. Since the 1990's robotic palletizers have begun to replace traditional layer palletizers as the cost of robotics technology has decreased substantially. At the same time, retailers looking to streamline operations and reduce inventory have increased their demands for custom-mixed pallet loads, creating a need for a flexible palletizing solution. Both layer palletizers and robotic palletizers find wide use in end- of-line packaging applications. The initial equipment cost for a single conventional vs. robotic palletizer can be comparable for the most basic system, and the system footprint is similar, although robotic palletizers typically require less floor space. However, as retailer demands for multi-SKU pallet loads increase and manufacturers continue to think in terms of sustainable packaging and “lean-and-clean” processes and facilities, the advantages of robotic palletizers make them ideal for most palletizing applications. The Problem with Layer Palletizers Conventional palletizing systems typically use a layering technique that forms the pack pattern of cases (or bags, or bundles), squeezes them into shape and deposits them one layer at a time onto the pallet. Low infeed palletizers receive cases at an infeed conveyor near pallet level and stack from the bottom up. A moving rack next to the pallet accumulates the cases into a pack pattern and moves them one layer at a time onto the pallet. High infeed palletizers receive cases from a conveyor located above the pallet, accumulate the cases on a tray above the pallet, and lower each layer into place. This solution works well in applications where a single product is palletized at a fairly high speed. However, it fails to address retailer demands for mixed pallet loads. In a traditional retail scenario, full pallets of a single type of product leave the manufacturer and arrive at the retailer's distribution center, where, according to the needs of individual stores, personnel break down the single-load pallets and custom-mix new pallets. To increase efficiency, more retailers now require manufacturers to ship custom-mixed pallets directly from the manufacturing plant. While layer palletizers can produce “rainbow” pallet loads that place a different product on each layer — one full

The Advantages of Robotic Palletizers Compared To Conventional Layer Palletizers