An Introduction to

Automated Palletizing

By
Michael A. Hernan I
Copyright: April 21, 2000

Published By:
Anderson Technical Services, Inc.
850 Morrison Road
Chillicothe, Ohio 45601
740-775-1962
www.atsi.cc
 An Introduction to Palletizing
“Choosing the Right System”
by
Michael A. Hernan I

Abstract

Machines that automatically place cartons onto pallets, called “Palletizers”, vary greatly
in design and functionality. Selection and comparisons can be difficult if the user does
not know some of the basic design and functional parameters of the different equipment
offerings.

This paper reviews the different types of Palletizers and how they are best applied.
Palletizers are not stand alone machines; they work best within an integrated system or in
a “cell “ concept. This paper looks at Palletizers in systems and in a cells plus reviews
the before (in- feed) and after (out-feed) design requirements. It lists the throughputs and
flexibility of each machine type listed and provides application comparisons.

This paper endeavors to inform the reader about the general capabilities and
specifications of different types of palletizer. It will help the reader identify many of the
necessary considerations to determine the best machine type for their specific application.

Introduction

This paper will focus on palletizing, which is a form of unitizing. Palletizing refers to a
uniform load stacked on a wooden pallet, using a pre-determined case pattern sequence
and given number of layers. Unitizing refers to any load forming or unit load building
process. Loads can be formed using the same stacking procedure as palletizing, without
necessarily using a pallet, or loads may be stacked on slip sheets or on the floor.

The process of palletizing typically involves the stacking of cases, trays, bundles, bags,
pails or drums in a predetermined pattern configuration with a predetermined number of
layers. This paper will focus on the use of cases only, as they make up the vast majority
of palletizing applications.

No matter what type of palletizing equipment is used, several factors are constant. Cases,
case patterns, pallets, along with slip, pull pack and tie sheets are things every palletizer
must contend with. Before we look at the different equipment types, we will review what
they have to handle.
Cases & Case Patterns

The palletizers we will review can handle products from a small as 5” to 6” square boxes
with as many as 64 cartons per layer, up to a single carton size of 50” x 40” stacked one
to a layer. The product weight per carton can vary from 2 pounds up to 250 pounds with
a full pallet loads ranging up to 6,000 pounds.

An ideal case for building a formed load, is one that is rectangular and has a height that
approximates the width of the case. A case with a height that is 1-1/2 times the width of
the case or greater is termed a “high center of gravity case”. In some applications special
attention is required in order to avoid tipping over “high center of gravity cases” during
pattern forming. Rectangular cases enable stacking configurations that create a load that
has each layer rotated 180-degrees for interlocking purposes. In this way a very stable
load is built.

Square cases are less desirable in pallet forming than rectangular cases. Loads built using
square cases can only be column stacked and no interlocking of the cases can occur.

A fully automated palletizer needs to have a high level

of sophistication to handle the many possible pallet
loading configurations. Some applications call for
only one pallet pattern, while other call for more than
20 patterns. Each pattern many have a different
number of layers and require a different size pallet. In
addition, the machine may have to account for slip
and tie sheets to be part of the finished load.

Some case sizes do not allow the patterns to be configured without gaps in the pattern
either side to side or front to back. However, the palletizer has the ability to create the
pattern with these gaps in both directions.

Slip, Pull Pack and Tie Sheets

The terms “slip sheets” and “pull sheets” are synonymous. (Please reference Exhibit I).
They refer to a sheet on which the load is stacked, in place of or on top of a pallet. This
sheet is generally made from heavy corrugated and requires a special lift truck
attachment, which enables the load to be moved by the lift truck. Conventional fork
trucks do not have this attachment and cannot be used.

Tie sheets refer to sheets that are placed between the layers of a load to obtain load
stabilization. These are used predominantly when the cases to be stacked are square
and/or no interlocking case pattern sequence can be employed. Tie sheets can be thin
“butcher” paper, corrugated or fiberboard.

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Pallets

For most applications, the machines must handle the most common pallets used in
palletizing, conventional 2-way and 4-way wooden pallets together with solid plywood
pallets (slave pallets), that are often used in AS/RS (Automated Storage & Retrieval
Systems) or AGV (Automatic Guided Vehicle) systems. (Please reference Exhibit I)
Recently more companies are using plastic reusable pallets. These actually help
palletizing effectiveness as they are offer more consistency between individual pallets
and are less prone to damage than wood pallets.

Defining Speed

In palletizing speed is always a relative term. Speed primarily depends

on the size of cartons to be handled, but is directly affected by the
system’s layout.

The assumption that the higher the price of the machine, the faster the
speed, is inaccurate. One of the basic fundamentals of palletizing is
that the more cases per layer, the faster the speed. Larger cartons
fill the pallet faster, thus making the palletizer appear faster. Smaller
cartons and intricate stacking patterns require more time.

Therefore, a machine that can handle a 12 case per layer pattern

configuration at a speed of 34 cases per minute may have a speed
limitation of 22 cases per minute for a 6 case per layer pattern
configuration.

The palletizer’s method of building a layer directly affects its speed. In-Line Palletizers
pick-up and move an entire layer, as opposed to a robotic–style machine that moves a
single case or two with each movement. Robotic Palletizers can build a load with a line
of waiting, accumulated, cartons faster than building with an intermittent flow of cartons
coming directly from production. Thus the infeed of cartons to the palletizer directly
affect its throughput speed. The same is true for the outfeed of cartons. If completed
pallets are not taken away fast enough the line becomes full and the palletizer has to stop.
The infeed and outfeed conditions directly affect all types of palletizers.

When considering speed requirements for a palletizing system, the rule of thumb is that
the palletizer- machine must be able to handle 25% more than the incoming packaging
line(s) can produce. Carton size, carton mix and the case pattern configuration must be
considered to calculate the palletizer speed with the aforementioned safety factor. This
“speed” must be based on round-the-clock operation and are sustainable speeds, not surge
rates.

Generally, when the manufacturer for a given model quotes speeds, they are based on an
8 to 10 case per layer configuration. A fully automatic low speed palletizer will operate

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at a speed of 10 to 25 cases per minute and on the upper end of the speed range,
palletizers are available that can handle 120 to 160 cases per minute.

A Systems Approach

An automated palletizer is rarely intended to function as a stand-alone unit. It is not a

commodity piece of equipment that can be judged or compared on it own, like a bay of
rack or shelving. Instead, it should be viewed as one component that is designed to fit
seamlessly into a larger, integrated materials handling or packaging system.

Regardless of the type of palletizer you select the interfaces both upstream and
downstream must match the rated operating speed of the palletizer or palletizing cell or
you new solution will cause more problems than it solves. After reviewing the
characteristics of each type of palletizer we will look at some typical systems layouts to
illustrate how they are used in everyday operations.

Palletizers
Types of Palletizers
The many different types of palletizing machines can
be categorized into two groups: In-Line and Robotic. In-Line Palletizers
Row Stripping
In-Line Palletizers offer speed while Robotic Palletizers
High Level
offer flexibility. Low Level
Vacuum Head
The approach to layout is different for In-Line &
Robotic Palletizers. Exhibit II illustrates the difference Robotic
Articulated Arm
and other examples are provided in this paper. (SCARA) Arm
Gantry (Cartesian)

In-Line Palletizers

These machines are dedicated to a line or lines to handle limited product/carton types.
The style you choose depends on your flow of cases at the end of the line and the type of
product you are handling.

Row-Stripping Palletizer
These are the most common machines. They are what most people envision when they
think of automated palletizing. These machines are designed for high speeds at
continuous duty.

This machine gets its name by the method it palletizes product. It first forms a row of
cartons. Once a row is completed, a pusher mechanism moves the row to the palletizer’s
make-up area. Several rows are combined to build a layer of products. To form the load,
the completed layers are stacked on a pallet or other unit load platform.

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Each row contributes to the building of a layer of cartons. Once a layer is complete, the
palletizer deposits it either to the bottom, if it is a low level unit or on top of another layer
if it is a high level unit.

Row stripers can produce very high throughput speeds; speeds that can reach 160 cartons
per minute. This type of palletizer can also palletize products of different shapes and
sizes, provided that they are not intermixed. This type of machine has two basic types of
infeed configurations: high level and low level.

High level machines have case entry elevations

from 7’-12’. They are more suited to situations
where the palletizer is located some distance
from the case packer or sealer, and an overhead
conveyor is required to transport the cases form
the case sealer to the palletizer. This type of
arrangement frees up a great deal of floor
space. (Please refer to Exhibit III). This is
especially important when you have a very high
speed operation (over 50 cases per minute) and
you have long conveyor accumulation line(s) feeding the machine.

Low level units have an entry elevation of approximately 30”. This makes it ideal for
close coupling to case packers and case sealers, which have discharge elevations of
anywhere from 20” to 36”. If you have abundant floor space, this type of arrangement
offers several advantages over high level machines.

As the infeed elevation is about waist high,

operators can monitor operations from the floor or
from a forklift. You can monitor machine
operations while filling the pallet magazine or
removing full loads from the discharge conveyor.
A high level machine requires a mezzanine with a
stairway since the operating portion of the machine
is at 7’-12’ above the floor. Jams will take longer to
detect and if a high level palletizer goes down for
any reason, it is far more difficult to hand stack,
since cases are entering the machine at such a high elevation. Maintenance work will
need to be done above on high level, where cases are turned and arranged into layers.

Biggest difference between low level and high level machines is that on low level
machines during the load building process, the elevator lifts one layer at a tine and the
load is built on a heavy-duty discharge conveyor, while the high level machine requires
an elevator to support the full load as it is being built. The added mechanical complexity
of a high level machine elevator results in more maintenance concerns compared to a low
level machine.

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Vacuum-Head Systems
At the infeed end of the palletizer, a layer-
makeup section within the machine forms the
products into layers prior to the stacking
operation. It uses stops and case turners to
rotate cases to form the desired pallet pattern.
Then a series of connected pneumatically
powered suction cups grip the entire
completed layer of products. Depending on the
product, a clam shell clamping device can be
used in place of the suction cups. The
palletizer then lifts the cartons as a group and
places them into a pallet.

Top operating speed for this type of palletizer is typically about 25 cartons per minute.
An ideal application for a vacuum- head palletizer is one in which it handles rigid
products with a sturdy, flat tops. It is also an excellent choice for bags, drums and pails.

In-Line Palletizer Applications

A single conveyor feeds the majority of palletizers from a packaging or production line.
This is why they are referred to as a dedicated machine. It is also common to have
several packaging lines feeding into one higher speed palletizer thereby reducing the
number of palletizers required. This arrangement is not unlike a funnel, pouring goods
quickly into a smaller opening. However, if the opening (palletizing operation) is too
slow or gets jammed, everything else upstream gets messy—quickly.

The need to accumulate product before and after palletizing is essential to smooth and
effective operations. When a single line is fed to a single dedicated palletizer, only the
product on that line is delivered to the palletizer. If the palletizer cannot keep- up or
pauses, the line backs-up, and eventually production on that line stops. When feeding
multiple product lines into a single high-speed palletizer back-up or pause in palletizing
can cause your operations to halt. That is why careful considerations must be given to
the accumulation. Please refer to Exhibits IV, V &VI for sample layouts that illustrate
this point.

The rule of thumb is to accumulate at least 1.5 times a full pallet load of each product
prior to feeding them to the palletizer. In the case of multiple product (conveyor) lines
being fed into a single high-speed palletizer, the palletizer must be capable of running at a
speed of approximately 10-20% greater than the total accumulated rates of each of the
conveyor lines feeding it. Thus, if three packaging lines, running at an accumulated rate
of 10 cases per minute per line were feeding into one palletizer, the palletizer must run at
10-20% faster than the 30 cases per minute being accumulated. In othe r words, the
palletizer must handle 33 to 36 cases per minute. This does not include the 25% safety
factor mentioned before.

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Accumulation Length
The length of each line of accumulation conveyors from production into the
packaging/palletizing cell should be 1.5, minimum to 2 times a full pallet load of product.
This allows additional accumulation while one line is metering cases to the palletizer.

Thus, if one packaging line is producing 16” long cartons and requires 80 cases to
complete a full load, this equates to a full load length of 107’ (1280” times 1.5, which
give a total accumulation conveyor length of 160’. This equation is repeated for each
additional line feeding the palletizer.

Robotic Palletizers

A robot’s strength is the ability to rapidly arrange mixed pallets while serving several
lines at the same time. These palletizers, depending on end-effector (end-of-arm-
tooling) can better handle thinner-walled corrugated and more fragile case. Robotic
Palletizers run at low to medium rates and are best used in applications that require a high
degree of flexibility, and intermixed product with different shapes and sizes. Speeds of 10
to 30 cases per minute are common.

If your operation requires different pallet patterns or uses different size cartons, the
controls and software programs for robotic palletizers give you the highest degree of
flexibility and quick reprogrammability you require.

There are three predominant types of robotic palletizers

Ø SCARA Arm
Ø Articulated Arm
Ø Gantry

All three types use end-effectors that are custom designed to handle the customer’s
product. Most often the design includes pneumatic cups, like the ones used by vacuum-
head palletizers; or they may use various types of mechanical grabs.

SCARA Arm Palletizers

SCARA (Selective Compliant Articulated Robot Arm)
robots have joints in the horizontal plane, which allows the
arm to swivel about its base and fold in on itself like a
"folding screen." Its work envelope is cylindrical. These
robots maneuver cartons through four-axis movement using
a mast and cross arm. The entire unit is often placed on a
pedestal on rails so the robot can palletize up to 6-8 pallets
at a time. (Please refer to Exhibit VII)

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Articulated Arm Palletizers
An articulated arm palletizer also features four-axis
movement, but relies on a mechanical arm equipped with at
least three or four rotary joints: waist, shoulder, elbow, and
wrist joints. This robot is an excellent choice for placing
mixed loads on 1-4 pallets at a time. Like a SCARA arm
robot this unit can also be placed on a pedestal on rails so it
can palletize additional pallets at a time. (Please refer to
Exhibit VIII& IX)

The layout configurations of these two “arm” type robots are very similar. (Please
review Exhibit II). In many cases they can be used interchangeably. Articulated arms
are better at building difficult intermixed loads on pallets, while SCARA arms are a bit
faster at building multiple pallet loads and usually cost less than articulated arm units.

Gantry Robot (Catresian) Palletizers

This unit uses a robotic arm placed on an overhead
structure, a gantry, to achieve four-axis movement.
The arm has three prismatic joints, whose axes are
coincident with a Cartesian coordinator. The arm or
end effector is mounted to a bridge that moves above
the loads. The arm can be a suction cup, gripper or
hybrid combination of the two. This palletizer is ideal
for palletizing 8-60 pallets at a time. If more speed is
required two or more bridges with arms can be place
on the gantry. (Please refer to Exhibit X, XI & XII)

Robotic Palletizer Applications

Robotic Palletizers, in a sense work opposite to dedicated In-Line Palletizers. Instead of

funneling multiple lines together, a robotic palletizer usually receives product from one
line and places cases on several pallets at a time. (Please refer to Exhibit II) Robotic
palletizers are seen most often in manufacturing applications where one- main production
line carries various product types from different production machines. They accumulate
at the end of the line and the robot places the correct product on the correct pallet. Two to
sixty pallets can be built simultaneously, depending on the type of robot used and the
throughput requirements of the system

The need to accumulate product before and after palletizing is still just as essential for
smooth and effective operations. The rule of thumb is to accumulate at least 1-1/2 full
pallet loads of product on the infeed line prior to feeding them to the palletizer. In the
case of multiple product (conveyor) lines being fed into a single robot palletizer, the
palletizer must be capable of running at a speed of approximately 10-20% greater than
the total accumulated rates of each of the conveyor lines feeding it. Thus, if three
packaging lines, running at an accumulated rate of 5 cases per minute per line were

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feeding into one palletizer, the palletizer must run at 15-25% faster than the 15 cases per
minute being accumulated. In other words, the palletizer must handle 17 to 20 cases per
minute. This does not include the 25% safety factor mentioned before.

Accumulation Length
The length of each line of accumulation conveyors from production into the
packaging/palletizing cell should be 1.5, minimum to 2 times a full pallet load of product.

Robots offer flexibility over speed. The infeed configurations are usually simpler than
In-Line Palletizers, however, the design of the palletizing cell is more critical. The
placement of the pallet(s), feeding pallets into and out of the system, all directly affect
throughput and systems’ functionality.

Other Considerations

An automated palletizer is usually part of a total packaging system. The palletizer may
have to interface or integrate with some of the following items:

Ø Case sealers
Ø Slip or tie sheet feeders
Ø Packaging machine
Ø Stretch wrappers
Ø Checkweighers
Ø Bar code labelers and applicators
Ø Pallet collector/dispensers
Ø Depalletizing

Often after installation as your system grows, demands for increased speed, flexibility
and capability happen. Often increases in speed are affected more by efficient system
configurations and changes in the inbound or outbound lines, than palletizer machine
speed.

Other challenges come with a specific stacking pattern for each type of product.
Sophisticated Palletizer Controllers can help to meet many of these challenges.

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Controls

The number of case patterns that can be programmed into a fully automatic palletizer is
virtually limitless. However, when a pattern is programmed into a palletizer, it is not
simply a software change in the controller itself. One of the biggest challenges
manufactures must meet is building loads to customer’s specifications. More vendors
are requiring manufactures to build the pallet load so the bar code labels are readable on
all cases after stacking. Programmable controllers, systems’ controls, and software must
work together to fulfill this requirement.

There are several ways to solve the problem. If your application requires cases and you
are not using Robotic Palletizing, the turning function can be achieved with turning posts
or more elaborate things like side flaps, rotators, or lifting rotators.

For In-Line Palletizers mechanical stops are required in the machine, in order to separate
the cases during pattern forming. The hardware involves more than the case stops
themselves, it also includes cylinders to operate the stops, pneumatic valves to operate
the cylinders, and the software program to control them. All of which means additional
cost when the numbers of case pattern sequences are determined.

For Robotic Palletizers, the considerations and costs are somewhat less. Additional axes
of rotations (extra joints) are added to the end-of-arm tooling or end effector. With
robotic palletizers, the label is read up stream of the palletizer, the data is collected, and
then information to turn the carton is transmitted to the robot’s operating software. The
robot then uses its rotors to stack the carton properly on the pallet

Advances in controls, both PC and PLCs (programmable logic

controllers) make synchronizing palletizers and conveyor lines
easier. Cases can be accumulated and released in slugs to the
palletizers, or cases can move in a single-speed line to be
arranged by the palletizers.

Like other kinds of material handling equipment, controls bring

better functionality to palletizers. You can find models with touch
screen operator interfaces. These screens make controlling,
maintaining and diagnosing problems very user friendly. No matter
what type of palletizer you use, the higher the throughput or the
more flexibility required, the more elaborate and the more critical the layout
configurations systems’ becomes. (Please also refer to Exhibit XIII)

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Why Automatically Palletize?

Automated palletizers are complex and expensive. In low throughput palletizing, 10

cases per minute or less, it is difficult to justify the cost of these machines using labor
savings alone. In moderate to high-speed operations, above 15 cases per minute, some
form of automated palletizing is the better choice.

When reviewing the justification of an automated palletizer, more than just direct labor
savings should be considered. The benefits produced by implementing an automated
palletizing operation are impressive:

Ø Increased line flexibility;

Ø Increased Throughput;
Ø Reduced worker injuries;
Ø Increased Load Accuracy;
Ø Better cube utilization;
Ø Tighter, more uniform pallet loads;
Ø Reduced handling- related product damage;
Ø Increased Line Speed.

All of these factors should be calculated into your return on investment (ROI) formula
when considering automating your palletizing/packaging operations.

Making the Right Decision

To make the correct palletizer purchase, it is essential to understand how your business
will change in years to come. The higher throughput capacity your system requires, the
more elaborate the palletizing scheme becomes. Plan ahead for accessories such as
turning devices, pre-forming zones, slip sheet feeders, pallet dispensers, or parallel line
feeds.

Table 1 is a chart that summarizes the speed and flexibility of the types of palletizers we
have reviewed. The best machine is dependant on ones requirements and future needs.
Like all major capital decisions, proper research and thought should be given to
operations requirements and overall goals of the project before sending out bid requests
or settling on a machine to purchase.

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Table 1:

Characteristics of Automated Palletizers

Operating
Stacking
Speed Degree of
Palletizer Type Capacity Height Comments
(cartons/ Flexibility
(ft)
minute)
In-Line
Row Stripping 250 lb/ctn FAST! Many manufactures
40-160 800 lb/layer 5.5 -10 Low offer both low level & high
6,000 lb/load level designs.
Vacuum-Head Typically used with
10-25 100 lb/ctn 6-7.5 Medium products that have flat, rigid
tops; or delicate product.
Robotic
SCARA Arm Excellent degree of
10-30 200 lb/ctn Up to 9 High
flexibility.
Articulated Arm Excellent for building
10-30 400 lb/ctn Up to 6 High intermixed loads on one
pallet.
Gantry Up to Excellent for building up to
10-30 400 lb/ctn High
12 60 pallet simultaneously

About the author:

Michael A. Hernan I is a designer and implementer of automation & ergonomic

systems. Mr. Hernans background is in project development, systems' design
and profit improvement. He has more than 20 years experience as a project
manager, design engineer, and consultant.

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 Exhibit I
Pallets &
Case Patterns

Using programmable controllers and advanced controls,

automated palletizers have the ability to stack loads in any
Interlocked load stacked number of pattern configurations. The also have the ability to
on a slip sheet only incorporate tie, slip, and pull sheets into the load configuration. Column stacked load on a
Loads can be built on pallets of all types, on slip sheets, or in the pallet slip with slip sheets
case of robotic palletizers, unitized on the floor.

Slave Pallet;
often used in AS/RS &
AGV applications 4-Way Pallet 2-Way Pallet
 Exhibit II
In Line Vs. Robotic Arm
Palletizers

This simple diagram illustrates a typical layout for a fully

automated In-Line Palletizer. In high speed applications
particular attention must be given to the design of the infeed and
outfeed materials handling system. If designed incorrectly
many problems in operations will occur.
This simple diagram illustrates a typical layout for a
robotic arm palletizer. The robot is on a pedestal
that moves on rails to build several pallets at once.

In robot applications, the layout of the cell is more

critical. The deign of the end-effector is a key
element in systems’ flexibility & capability.
 Exhibit III
Row Stripper Palletizer
High Level

These pictures illustrate the

“make-up” area of row
stripping machines. A series
of stops and turning devices
forms a row. A stripping
device places the layer on the
pallet.

Row Stripper palletizers are built for speed. A

Shown on this page are high level
machines. The center diagram shows a
machine with a automated pallet
dispenser, high level infeed and in- line
make-up area.
row of cartons is assembled before the unit.
Once a row is completed, a pusher mechanism
moves the row to the palletizer’s make-up area.
Several rows are combined to build a layer of
products. To form the load, the completed layers
are stacked on a pallet or other unit load
platform.
Each row contributes to the building of a layer
of cartons. Once a layer is complete, the
palletizer deposits it either to the bottom, if it is
a low level unit or on top of another layer if it is
a high level unit.
 Exhibit IV
Row Stripper Palletizer
High Level

To have an effective palletizing operation Row Strippers need long accumulation lines to feed the machine. They can palletize different products,
but are limited to one product or pattern per pallet. Thus long accumulation lines for each product is required.

The layout above illustrates a typical arrangement for a high level row stripping machine. The infeed lines enter the machine at a high elevation
(10’-12’), thus saving valuable floor space.

The oufeed is equally important. This layout uses a shuttle transfer (T-Car) to take full loads from the palletizers to a stretch wrapper. After
stretch wrapping they accumulate on an a staging conveyor and await removal by lift truck.
 Exhibit V
Row Stripper Palletizer
Low Level

The layout above illustrates a typical arrangement for a low level row stripping machine. The infeed lines enter the machine at a low elevation
(24”-36”), making it easier for maintenance and jam detection.

Like all row stripping machines, to have an effective operation they need long accumulation lines to feed the machine. They can palletize
different products, but are limited to one product or pattern per pallet. Thus long accumulation lines for each product is required.

The oufeed is equally important. This layout uses a shuttle transfer (T-Car) to take full loads from the palletizers to a stretch wrapper. After
stretch wrapping they accumulate on an a staging conveyor and await removal by lift truck.
Exhibit VI
Vacuum Head

This layout illustrates a typical arrangement for a vacuum head

machine. The layout approach is very much like a low level
row stripping unit. Like all in- line machines, to ha ve an
effective operation they need long accumulation lines to feed
the machine. They can palletize different products, but are
limited to one product per layer. Because they use a suction
cup or clap device to lift an entire layer some intermixing of
product on a pallet is possible..

The oufeed is less critical in this machine because the rates are
not as fast. This layout shows a small length of staging
conveyor at the exit end of the palletizer where full pallets
await removal by lift truck.
 Exhibit VII
SCARA Arm
Palletizer Layouts

This illustration details a SCARA Robot palletizing cell. This cell accounts for future the
growth of the operations. This is an excellent example of palletizing in a “cell concept”.

The robot has the capability of handling an additional production line. Semi-automated at
present, the addition of pallet dispensers, exit conveyors and a lift table will make this
palletizing operation fully automated.
 Exhibit VIII
Articulated Arm Robot
Palletizer Layouts

From
Production

The layout above illustrates a typical arrangement for a Articulated Arm Robot.
The robot can palletized multiple pallets at one time handling different loads.

A single end effector can be designed to handle cartons, slip sheets and pallets.
Good end effector design adds greatly to the versatility of these machines.
 Exhibit IX
Articulated Arm Robot
Palletizer Layouts

The layout above illustrates the robot building intermixed loads by depalletizing
existing-built pallets on the floor and palletizing a new pallet on a production
conveyor.

The picture shows a palletizing cell that palletizes product from three
production lines. The line drawing shows a unit that builds intermixed loads
from a single main production line.
 Exhibit X
2& 3-Axis Gantry
Palletizer Layouts

A gantry can come in 2, 3 or 4-axis configurations. The one shown to the right
has an x,z, and r axis. Different end effectors shown above-right allow for robot
style palletizers to handle almost any type of product and allows for superior
operations flexibility.

The layout above shows a 2-axis gantry palletizing cylinders. The advantage of a
gantry is the ability to stack loads high and to build many pallets at a time. The
layout approach to gantries is somewhat different than arm robots, but the overall
design philosophy is the same.
 Exhibit XI
4-Axis Gantry
Palletizer Layouts

A 4-axis gantry allows for great flexibility in manufacturing palletizing

operations. On this page all pallets are placed and taken away in the gantry cell
by fork lift. The drawing shows a layout where product is sorted before
palletizing. Then two pallets can are built simultaneously. Intermixed product
comes from one main production line.

The fish-eye picture to the right shows reusable totes filled with production parts
being palletized. The loaded pallets move to the end of the line where they
accumulated and await pickup by a forklift.
 Exhibit XII
4-Axis Gantry
Palletizer Layouts

The layout to the far right is a classic

example of a 4-axis gantry palletizing
24 pallets. This fully automated system
includes a transfer (T-Car) on rails that
feeds the cell empty pallets and takes
away full pallets.

Intermixed product comes from one

main production line. The product’s
bar code is scanned and the information
transmitted to a robot controller. The
carton is identified, then pick-up and
transported to the proper pallet, where
it is built into the proper case
configuration or pattern.

At the outfeed, the T-Car brings full

pallets onto an exit conveyor system
that brings loads to a stretch wrapper.
After wrapping, the pallet travels onto
accumulation conveyor where loads
wait for transportation to the warehouse
by forklift.
 Exhibit XIII
Palletizer
Controllers

Programmable controllers and software allow palletizers to handle limitless case and forming
patters. The flexibility and capability of palletizers is greatly enhanced by their use.

User friendly graphics and touch screen interfaces make palletizers easy to change pallet
configurations or handle different products. However, it must be remembered the machine must
also have the physical capabilities to execute the controllers commands.