Automatic palletizers are essential end-of-line machines that automatically organize, stack, and secure finished products onto pallets. They are designed to automate the strenuous, repetitive task of manual stacking, dramatically increasing efficiency, speed, and load stability.
Here is a breakdown of what automatic palletizers can do and what they can handle (the types of products and materials):
What Automatic Palletizers Can Do?
The primary function is stacking, but modern automatic palletizers perform several integrated tasks to create a ready-to-ship unit load:
1. High-Speed Stacking and Load Formation
Layer Formation: They efficiently take individual products (cases, bags, etc.) and group them into a precise layer pattern according to the programmed recipe.
Pattern Optimization: They can build complex, interlocking stack patterns (like brick-stacking) that maximize load stability and minimize shifting during transport, which is far superior to simple columnar manual stacking.
High Throughput: They operate continuously and at speeds far exceeding manual labor, often handling rates from 10 cases per minute (low-speed) up up to 100+ cases per minute (high-speed).
2. Product Manipulation and Preparation
Orientation and Turning: They automatically rotate or turn products (90° or 180°) as needed to fit the specified stacking pattern.
Slip Sheet/Tie Sheet Insertion: They can automatically place non-slip sheets or cardboard sheets between layers or on top of the final stack to add stability, protect products, or prevent movement.
Pallet Management: They interface with pallet conveyors and automatic pallet dispensers to introduce empty pallets and remove full ones without human intervention.
3. Quality and Integration
Consistent Quality: Every placement is precise and repeatable, ensuring uniformity across all stacked pallets.
SKU Versatility (Robotic): Modern robotic palletizers can be programmed to switch between dozens of different product sizes (SKUs) and stacking patterns quickly via software changeovers.
End-of-Line Integration: They are often the central component in a fully automated end-of-line system, communicating seamlessly with upstream packaging machines and downstream automatic stretch wrappers.
What Automatic Palletizers Can Handle (Products and Materials)?
Automatic palletizers are generally categorized by the product they are designed to handle:
1. Boxes and Cartons (Most Common)
Description: Standard rectangular boxes, corrugated cartons, trays, and plastic totes.
System Type: Best handled by both Robotic Palletizers (for flexibility and precision) and Conventional (Layer) Palletizers (for very high-speed, uniform stacking).
2. Bags and Sacks (Challenging Products)
Description: Products like cement, flour, chemicals, grain, feed, or coffee sacks, which are flexible and change shape during handling.
Handling Requirement: Requires specialized grippers (clamp-style or finger grippers) and often vibrating plates or conditioners to flatten the bag before stacking for better stability.
3. Pails, Drums, and Buckets
Description: Round containers of liquids, powders, or chemicals.
Handling Requirement: Requires custom End-of-Arm Tooling (EOAT) with specialized claws or vacuum grippers designed to grip the side or lid securely and often requires specialized software to manage the non-square stacking patterns.
4. Beverage Cases, Shrink-Wrapped Trays, and Bottles
Description: Used heavily in the food and beverage industry for stacking trays of cans, cases of bottles, or shrink-wrapped multipacks.
Handling Requirement: Requires high-speed, gentle handling to prevent product damage or rupture of the wrapping.
5. Large, Bulky, or Heavy Items
Description: Items like tires, rolls of paper or film, or custom manufactured parts.
Handling Requirement: Often requires heavy-duty Gantry (Cartesian) Palletizers or large, high-payload articulated robots, equipped with powerful customized grippers or magnets.
