What is palletizing? Stages, types and composition

Palletizing is the process of stacking products on pallets for storage or transportation. It can also be done manually, with workers stacking the product by hand. Although this method provides flexibility, it is labor intensive, does not optimize throughput, and does not increase operator injuries. Alternatively, the palletizing process can be fully automated using robots. Robotic palletizers can take many forms. On the one hand, there are large-scale inline palletizers that handle high throughput and large volumes, and on the other hand, there are cobot arms that provide adaptability to handle different package sizes and volumes.

Steps involved in palletizing

Palletizing involves several steps with variables and optional steps depending on specific requirements. The main steps are:

1. Step 1: Product preparation

Make sure products are properly packaged and labeled. This step may include quality checking and item sorting.

2. Step 2: Select Palette

Choosing the right pallet is key to the reliability, safety and efficiency of your palletizing, transportation and material handling processes. Pallets come in wood, plastic, and metal, each with their own advantages. Wood provides strength and economy, plastic provides durability and moisture resistance, and metal can withstand heavy or high-temperature loads. Your choice will depend on cargo type, weight and handling requirements.

3. Step 3: Preparation Plan

Efficient pallet layout requires careful planning to optimize space utilization and stability. The boxes are placed with weight distribution and ease of access in mind. Consider shape, size and packaging to determine the best pattern while facilitating loading and unloading to increase operational efficiency. This step can be done with the help of software.

4. Step 4: Stacking and securing luggage

Execute your placement plan – stack products on pallets as planned. The use of stretch film reduces the risk of damage and ensures the safety of handlers during loading and unloading.

5. Step 5: Labeling and Documentation (Optional)

Product labeling and documentation are the final palletizing steps to increase shipping efficiency and provide compliance and product traceability. Pallets are labeled with information such as contents, weight, and handling instructions. Additional information may be provided to indicate country of origin and batch number. Marking packaging and supplying product documentation simplifies logistics and customs clearance.

6. Step 6: Quality Check (Optional)

We perform final inspections to ensure that palletized cargo meets all safety and quality standards.

Advice on determining the steps required for palletizing

Consider factors such as product type, transportation method, and material handling requirements to determine which steps are essential to your palletizing process. Consulting with an expert can help tailor the process to fit your specific needs.

Types of Automatic Palletizers

Automatic palletizers are increasingly preferred over manual palletizers due to their many advantages. These systems stack product faster and more efficiently than workers, significantly increasing productivity. In addition to reducing labor costs, it helps minimize workplace injuries caused by repetitive movements and lifting. Automatic palletizers increase the accuracy and uniformity of stacking patterns, improving pallet stability and space efficiency. It can operate continuously, helping to increase production. As technology advances, these systems have become more adaptable, capable of handling a variety of product types and sizes. For industries facing labor shortages or increased production demands, automatic palletizers provide a reliable, cost-effective solution that improves both operational efficiency and product quality.

There are two main types of automatic palletizers:

• inline palletizer
  Inline palletizers use stationary machines and conveyor systems to arrange products on pallets. The products move along a conveyor and are moved into several layers and then stacked on pallets. Ideal for high-speed, high-volume work. They are usually fully automated, but some models may be semi-automated.

• robot arm palletizer
  Robotic arm palletizers use automated arms to pick up products and place them on pallets. It offers high flexibility and can handle a variety of product shapes and sizes. Ideal for industries with diverse product lines or frequent changes. Depending on your setup and requirements, it can be fully automated or semi-automated.

Palette Configuration

Pallet configuration refers to how items are arranged on a pallet. This includes data on pallet type and size, stacking pattern, layer height, and number of cases per pallet and row. The main configuration patterns are:

• pillar stacking
  Items are stacked directly on top of each other while maintaining the same footprint on the pallet. This method maximizes stack strength and stability. They are best suited for light or fragile items, which can easily topple over if stacked too high.
• bricklaying
  Alternately change the orientation of items in each layer to create a brick-like structure. This approach provides a robust, move-resistant stack. You can mix box sizes, but this may reduce the total number of boxes per pallet.
• interlocking pattern
  The item uses rotation space supported by several boxes below. This method provides excellent stability for high density loads. Provides better bridging strength. Configurations can be more complex. Uneven pressure may be applied to individual boxes.

Each pattern has its advantages and is chosen based on the specific requirements of material handling, palletizing processes and logistics requirements. Need help choosing a pallet pattern? Try the Robotiq configurator. equipment.

conclusion

Simplify your palletizing tasks with expert advice. Whether you are new to robotic palletizing or looking to optimize, our experts can assess your needs and recommend a solution. From equipment selection to integration, we can help you increase efficiency and reduce costs. Unleash the full potential of your logistics with automated palletizing. Contact us today.