Automatic palletizer – Automatically stacks goods on pallets

Automatic palletizer

An automatic palletizer is an automated system designed to lift, move, and stack goods packed in cartons or blocks onto pallets (wooden or plastic bases for loading goods) without direct human intervention.

About automatic palletizer

Automatic pallet stacker definition

It is a system that combines hardware (mechanical, robotic, sensor) and control software. It is capable of automatically identifying, lifting, moving, and stacking cartons or blocks on pallets in a defined sequence and location.

Programmed for continuous operation and automatically adjusts to the requirements of the queuing process.

Benefits of using an automatic palletizer

  • Continuous operation at a much higher speed than manual stacking
  • Reduce the time and manpower required for the queue stage
  • Stack cartons accurately, evenly and stably on pallets
  • Minimize the risk of cargo damage due to improper stowing
  • Eliminates the heavy, repetitive work associated with lifting and stacking bins
  • Avoid injuries caused by collisions, manual transportation
  • Reduce the need for labor for the queue stage
  • Optimize the use of factory and warehouse space
  • Easily track and record production and performance data
  • Analyze data to improve processes and make timely decisions
Improved packaging safety and quality
Improved packaging safety and quality

With these significant benefits, automatic palletizers are increasingly being widely used in manufacturing plants, logistics warehouses, and distribution centers to improve competitiveness and operational efficiency.

Working Principle of Automatic palletizer

Automatic palletizer control technology and software

Sensor system: Using physical sensors such as optical, ultrasound, and laser sensors to detect the position and size of cartons/blocks to be stacked. Some systems may use camera and image processing systems.

Programmable Controller (PLC): It is the brain that processes signals from sensors and controls the operation of mechanical assemblies such as lifting robots, conveyors, and slewing cranes,…

Control Software: PLC control programming software, which sets the optimal algorithms and queuing procedures. It can connect to a warehouse management system (WMS) to receive orders and track.

User Interface: Control screen for monitoring, monitoring, and intervening (if necessary) in the operation process.

Automatic palletizing process

  • First, the sensor system will scan and recognize the location and size of the cartons/blocks to be stacked
  • This data is sent to the PLC to calculate the optimal stacking position on the pallet according to programmed algorithms
  • PLC controls mechanical assemblies such as lifting robots, conveyors, cranes to move and load cartons/blocks on pallets according to the calculated sequence
  • The sensor continuously responds to the PLC to adjust the stacking position until the pallet is full
  • Queue data is sent to the management software to update the warehouse status
  • The process repeats for the next pallet.

The entire process is fully automated with minimal human intervention. This increases productivity, quality and minimizes the risk of errors compared to manual stacking. Technologies such as artificial intelligence and machine learning are also applied to optimize the queuing process.

Advantages of Using Automatic palletizer

Optimize storage and transportation space
Optimize storage and transportation space

The use of automatic palletizers offers many significant advantages over manual stacking, including:

Increase productivity and work efficiency

  • Automatic pallet stackers are capable of working continuously 24/7 at much higher speeds than manual palletizing
  • Significantly reduce the time required for loading and unloading goods, shorten production and delivery cycles
  • Greatly increase the productivity and efficiency of the loading process, helping to meet the needs of timely production and delivery.

Reduce errors due to human factors

  • The palletizer is precisely programmed, which ensures uniform and stable loading on pallets
  • Eliminate errors caused by human fatigue, distraction, or lack of concentration when manually stacking
  • Minimize the risk of cargo damage due to improper strolling or instability when moving.

Save time and labor costs

  • Significantly reduce the need for labor for the loading and unloading of goods on pallets
  • Save on salary, welfare, and training costs for the manual queued workforce
  • Make the most of human resources that can be transferred to other jobs with higher added value

In addition, automatic pallet stackers also offer a number of other benefits such as:

  • Increase competitiveness and responsiveness for businesses
  • Reduce the risk of injury to workers because they do not have to lift heavy goods
  • Optimize the use of space in factories and warehouses
  • Easily track, manage processes, and collect operational data

Thanks to these outstanding advantages, automatic palletizers are increasingly being widely used in the manufacturing and logistics industries to improve operational efficiency.

Popular Types of Automatic palletizer

There are several common types of automatic palletizing machines used in factories and warehouses as follows:

Side-loading pallet machine

  • The machine works by moving the cartons horizontally onto the pallet
  • Robotic systems or swivel cranes are often used to lift and push cartons onto pallets
  • Suitable for goods with uniform carton size
  • Advantages: fast stacking speed, high efficiency with uniform goods.

End-loading pallet machine

Increased productivity and efficiency of cargo handling
Increased productivity and efficiency of cargo handling
  • The machine moves and stacks cartons vertically onto pallets
  • Use a conveyor system or sliding table to push the bin into the stacking position
  • Suitable for goods with different carton sizes
  • Advantages: flexible with a variety of carton sizes

Omni-directional pallet stacker

  • The machine is capable of stacking cartons in various directions on pallets
  • Use a robotic system or multi-directional jib crane to lift and rotate the barrel.
  • Suitable for environments with many types of goods, different sizes of barrels
  • Advantages: high flexibility, can stack many different types of goods on the same pallet.

In addition, there are types of automatic pallet stackers combined with automated warehouse systems or self-propelled forklifts to form a fully automated production and distribution line of goods.

Choosing the right type of palletizing machine depends on the characteristics of the goods, the scale of production, the factory space and the productivity requirements of each business.

Choosing the right automatic palletizer

Choosing the right automatic palletizer is an important decision that affects the operational efficiency of your business. Here are some key factors to consider:

Consider the needs and requirements of the business

  • Evaluate cargo flow, production scale to estimate pallet loading and unloading needs
  • Determine the types of goods, sizes, and weights of the carton to choose the right machine
  • Evaluate the available space in the factory, warehouse to place the palletizer
  • Consider the need to integrate with existing logistics and inventory management systems

Calculation of investment costs and economic efficiency

  • Estimate the cost of procurement, installation, operation and maintenance of palletizing machines
  • Evaluate labor cost savings, increase productivity to calculate ROI (return on investment)
  • Compare cost and efficiency between different machine choices to make sound investment decisions
  • Consider policies to support and incentives for investment in automation machinery

Ensuring the performance and durability of palletizers

  • Choose a machine with features that are suitable for your business’s loading and unloading process
  • Prioritize highly reliable and durable machines from reputable brands
  • Evaluate the ability to expand and upgrade machines to meet future growth needs
  • Consider technical support, provide supplier spare parts.

In addition, it is also necessary to consider factors such as ensuring occupational safety, compliance with legal regulations, and the possibility of integrating automation in the future,… to choose the most suitable and efficient palletizing machine solution.

Please contact us immediately to receive professional advice and optimal solutions for your needs.

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