Manual Palletising Efficiency Problems and How to Overcome Them

Posted on September 1, 2024 by Granta

Manual palletising, where workers physically stack products onto pallets, is a staple in many industries due to its flexibility and straightforward approach. However, it’s also fraught with challenges that can hinder efficiency, increase costs, and put workers at risk of injury. While manual palletising has its place, the growing demand for higher productivity, consistency, and safety has led many businesses to explore automation as a solution. In this article, we’ll dive into the common efficiency problems associated with manual palletising and discuss how integrating automated palletising systems can help overcome these challenges and optimise operations.

Common Manual Palletising Efficiency Problems

1. Inconsistent Product Placement

Inconsistent product placement is a frequent issue in manual palletising that can lead to unstable loads, increased risk of product damage, and inefficient use of pallet space. These inconsistencies arise from human error, fatigue, and the absence of standardised procedures.

Causes:

  • Human Error and Fatigue: Variations in stacking due to worker fatigue or differing techniques.
  • Lack of Standardised Procedures: Without clear guidelines, workers may develop their own methods, leading to uneven stacking.

Solutions:

  • Implement Standardised Stacking Guidelines: Establish clear protocols for stacking to ensure uniformity.
  • Adopt Automated Palletisers: Automated systems can eliminate inconsistencies by precisely aligning and placing products on pallets. These machines are programmed to follow specific stacking patterns, ensuring every pallet is uniformly packed, reducing the risk of load instability and product damage.

2. High Labor Costs and Productivity Issues

Manual palletising is labour-intensive, with costs rising as demand increases. Productivity can vary significantly among workers, leading to inefficiencies and potential bottlenecks.

Causes:

  • Varied Worker Speeds: Different workers have different paces and efficiencies.
  • Physical Limitations and Fatigue: The repetitive and strenuous nature of the work can slow down productivity.

Solutions:

  • Optimise Workforce Allocation: Assign tasks based on strengths to balance productivity.
  • Implement Automated Palletisers to Reduce Labor Costs: Automated systems can handle the repetitive and physically demanding tasks of palletising, significantly reducing the need for manual labour. This not only cuts down on labour costs but also ensures a consistent and high productivity level, as machines can operate at a steady pace without fatigue.

3. Bottlenecks in Production Flow

Bottlenecks occur when the speed of manual palletising cannot keep up with the rest of the production line. This leads to delays, increased lead times, and overall reduced efficiency.

Causes:

  • Mismatch Between Production and Palletising Speed: Manual palletising often can’t match the speed of automated production lines.
  • Inefficient Workflow Design: Poor layout and organisation slow down the process.

Solutions:

  • Balance Production and Palletising Speeds: Adjust workflow and staff levels to align speeds.
  • Synchronise with Automated Systems: Automated palletisers can be calibrated to match the speed of your production line, virtually eliminating bottlenecks. These machines can handle high-speed operations, ensuring that products are palletised as quickly as they are produced, thereby maintaining a seamless flow in the production process.

4. High Risk of Injury

The physically demanding nature of manual palletising puts workers at a significant risk of injury, particularly when lifting heavy items or performing repetitive motions. Injuries can lead to downtime, increased workers’ compensation costs, and a loss of skilled labour.

Causes:

  • Repetitive Strain: Continuous lifting, bending, and twisting can cause injuries.
  • Improper Lifting Techniques and Overexertion: Lack of proper training and the pressure to work quickly can lead to accidents.

Solutions:

  • Provide Ergonomic Training and Tools: Train workers on proper techniques and provide aids like lifting tools.
  • Minimize Injury Risk with Automation: By automating the palletising process, you significantly reduce the physical strain on workers. Automated palletisers handle the heavy lifting and repetitive tasks, which greatly decreases the risk of workplace injuries. This not only protects your workforce but also reduces downtime and associated costs from injury-related absences.

5. Inefficient Use of Pallet Space

Inefficient stacking during manual palletising can lead to wasted pallet space, resulting in increased transportation and storage costs. Improper stacking patterns may also lead to unstable loads, risking product damage.

Causes:

  • Lack of Consistent Stacking Patterns and Planning: Without standardised approaches or pre-planned layouts, space is often wasted.
  • Product Variability: Different product sizes and shapes complicate uniform stacking.

Solutions:

  • Standardize Stacking Patterns and Plan Layouts: Train workers to follow optimised stacking patterns.
  • Optimise Space Utilisation with Automated Palletisers: Automated systems use advanced software to calculate the most efficient stacking patterns, ensuring maximum use of pallet space and stable loads. These machines can adjust for product variability, creating optimised stacks that reduce the number of pallets required and lower transportation and storage costs.

6. Fatigue and Reduced Productivity Over Time

Manual palletising is exhausting work, and as workers tire, their productivity and the quality of their work decline. Fatigue can also lead to mistakes and accidents, further reducing efficiency.

Causes:

  • Physical and Mental Exhaustion: Repetitive and physically demanding tasks lead to quick fatigue.
  • Monotonous Tasks and Long Shifts: Extended periods without rest reduce productivity and increase the likelihood of errors.

Solutions:

  • Ensure Adequate Rest Periods and Rotate Tasks: Implement regular breaks and rotate tasks to reduce fatigue.
  • Increase Productivity with Automation: Automated palletisers can operate continuously without suffering from fatigue, ensuring a consistently high level of productivity. By handling the most physically demanding tasks, automation allows your human workforce to focus on more skilled, value-adding activities, improving overall operational efficiency.

Manual palletising, while still widely used, comes with numerous challenges that can hinder efficiency, increase costs, and pose risks to workers. Inconsistent product placement, high labour costs, bottlenecks, injury risks, inefficient pallet space usage, and worker fatigue are just some of the issues that can arise in a manual system.

While there are strategies to mitigate these problems, such as implementing standardised procedures, optimizing workflows, and investing in ergonomic tools, integrating automated palletising systems can offer more comprehensive and long-term solutions. Automation not only addresses the specific challenges of manual palletising but also enhances overall productivity, reduces operational costs, and creates a safer work environment.

If you would like to know more about the Granta palletising systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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Strategic Risk Management for CapEx Managers in Manufacturing

Posted on August 15, 2024 by Granta

As a Capital Expenditure (CapEx) manager in the manufacturing industry, you are entrusted with steering substantial investments in machinery, infrastructure, and long-term assets that are vital to your company’s growth and operational efficiency. However, these high-stakes projects are fraught with risks—technical failures, budget overruns, supply chain disruptions, and regulatory hurdles—that can derail even the best-laid plans. To safeguard these investments and ensure projects are executed flawlessly, a robust risk management strategy is essential. This article delves into two critical components of that strategy: risk assessment and contingency planning.

Risk Assessment: Identifying and Mitigating Potential Threats

1. Comprehensive Risk Identification

The cornerstone of effective risk management is a thorough identification of all potential risks that could compromise your capital projects. This process demands a detailed examination of every aspect of the project, leaving no stone unturned:

  • Technical Risks: Consider the reliability and integration of new technologies and equipment. A single malfunction can lead to costly downtime and expensive repairs. For instance, investing in cutting-edge robotics without fully understanding its compatibility with existing systems could spell disaster.
  • Financial Risks: Beyond basic budgeting, you need to anticipate unexpected cost escalations, fluctuating material prices, and potential scope changes. Underestimating these factors can lead to financial haemorrhaging and, in the worst-case scenario, project abandonment.
  • Operational Risks: New projects often disrupt ongoing operations. The challenge is to ensure that these disruptions do not cripple your existing production capabilities. This requires careful planning and coordination to maintain a balance between the new and the ongoing.
  • Legal and Regulatory Risks: Navigating the maze of compliance regulations is non-negotiable. A minor oversight can lead to hefty fines, legal battles, and reputational damage.
  • External Risks: Externalities such as market volatility, supply chain vulnerabilities, and geopolitical tensions can have a domino effect on your project’s success. These factors are often beyond your control, making them even more critical to plan for.

Engage all relevant departments—engineering, procurement, finance, legal—to ensure a 360-degree view of the potential risks. Tools like SWOT analysis and PESTLE analysis are indispensable in systematically uncovering threats and opportunities, offering a strategic blueprint for your risk assessment.

2. Risk Evaluation and Prioritisation

After identifying potential risks, the next step is to evaluate and prioritise them based on their likelihood and potential impact. Utilise a risk matrix to visually map out these risks, where each is positioned according to its probability of occurrence and the severity of its consequences.

High-priority risks, such as a critical supplier’s financial instability, must be addressed immediately. These are the risks that can stop your project dead in its tracks. For example, a delay in receiving crucial components can cause a ripple effect, delaying the entire project and inflating costs.

3. Risk Mitigation Strategies

Risk mitigation is not about eliminating risk altogether—that’s impossible. It’s about making calculated moves to minimise the impact of those risks. Consider the following strategies:

  • Avoidance: In some cases, the best approach is to steer clear of certain risks altogether. This might mean choosing tried-and-tested technology over cutting-edge innovations that are still unproven.
  • Reduction: Implementing safeguards to reduce the likelihood of a risk occurring or to lessen its impact if it does. For example, performing rigorous supplier vetting processes can significantly mitigate the risk of supply chain disruptions.
  • Transfer: Transferring risk is a strategic move—whether by outsourcing certain risky activities to specialists or securing insurance to cover potential losses. This shifts the burden away from your organisation and onto third parties.
  • Acceptance: There are risks that must be accepted as a cost of doing business. For these, ensure that you have strategies in place to handle their impact when they arise, such as keeping a reserve fund for inevitable cost overruns.

Contingency Planning: Navigating the Unknown

1. Developing a Robust Contingency Plan

Contingency planning is about preparing for the unexpected. It’s not a matter of if things will go wrong, but when. A solid contingency plan will enable you to respond swiftly and effectively when the unforeseen happens. Key elements of a strong contingency plan include:

  • Trigger Points: Clearly define what circumstances will activate your contingency plan. This might include project delays, budget overruns, or critical path disruptions.
  • Alternative Strategies: Develop and document alternative actions that can be taken to mitigate the impact of unforeseen events. For example, if a key supplier fails, you should have a list of secondary suppliers ready to step in.
  • Resource Allocation: Ensure that resources—both financial and human—are earmarked and can be quickly mobilised in response to a crisis.
  • Communication Plan: Establish a clear communication protocol to keep all stakeholders informed and aligned during a contingency event. This reduces panic and ensures that everyone knows their role in the response.

2. Budgeting for Contingencies

Contingencies are often treated as an afterthought, but they should be an integral part of your budgeting process. Allocate a portion of your project budget to cover unexpected costs. This contingency fund should be based on a realistic assessment of the project’s risk profile. A well-calculated reserve can be the difference between a project that recovers from setbacks and one that flounders.

3. Continuous Monitoring and Adjustment

Risk management and contingency planning are not set-and-forget activities. They require continuous monitoring and adjustment throughout the project lifecycle. Regularly review your risk assessments and contingency plans to ensure they remain relevant as the project evolves and new risks emerge.

Implement a system of key performance indicators (KPIs) to track project progress and detect early signs of trouble. These KPIs act as the canaries in the coal mine, giving you the early warning signals needed to activate your contingency plans before a minor issue becomes a major crisis.

4. Scenario Planning

Scenario planning is a powerful tool for stress-testing your contingency plans. Simulate potential crises, such as a major supplier going bankrupt or a sudden regulatory change, to see how your plans hold up. This exercise will reveal gaps in your planning and help your team develop the muscle memory needed to respond quickly and effectively when real problems arise.

Managing risk in capital projects is about anticipating the challenges that could threaten your investments and taking decisive actions to mitigate those risks. By conducting thorough risk assessments, prioritising potential threats, and implementing robust contingency plans, you position your projects for success, even in the face of adversity. As a CapEx manager in manufacturing, your role is not just to oversee the allocation of capital but to ensure that these investments deliver their intended value despite the uncertainties that come with large-scale projects. Armed with the strategies outlined in this article, you can confidently navigate the complex landscape of capital project management and safeguard your company’s future.

If you would like to know more about the Granta palletising systems or AMR/AGV systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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Box Palletising: Cobot, Compact, and Modular Robotic Palletiser Systems

Posted on August 14, 2024 by Granta

In today’s fast paced manufacturing and logistics landscape, the efficient palletising of boxes is essential for optimising space, reducing labour costs, and ensuring smooth operations. Traditional palletising methods often struggle to meet the evolving demands of today’s fast-paced industries.

Each of the Granta box palletising systems offer unique advantages, from maximising efficiency in limited spaces to enhancing safety and flexibility through human-robot collaboration, and providing adaptable, scalable solutions for dynamic production environments. Understanding the merits of these innovative palletising systems can help you choose the right technology to optimise your operations.

Cobot Palletisers:

Cobot palletisers are increasingly becoming the go-to solution for businesses that require a blend of automation and human interaction in their palletising operations. This dual-mode capability allows the cobot to optimise both speed and payload capacity, depending on the operational requirements.

Key Features of the Granta Cobot Palletising System:

  1. 30kg Payload Collaborative Robot: The Granta system is equipped with a robust cobot capable of handling up to 30kg, making it suitable for palletising a wide range of box sizes and weights.
  2. Sturdy Industrial Design for 24/7 Use: Built for continuous operation, the Granta cobot is designed to withstand the rigors of industrial environments, ensuring reliable performance around the clock.
  3. Easy Programming Software: The system includes intuitive programming software, allowing operators to set up and adjust palletising tasks quickly without requiring extensive training or expertise.
  4. Variety of Gripper Options: The Granta cobot can be equipped with a variety of vacuum grippers to handle different types of boxes and packaging, providing flexibility for various palletising applications.
  5. Quick Installation: The system is designed for rapid deployment, minimising downtime and allowing businesses to start improving their palletising process quickly.
  6. Optional Guarding: Depending on the specific safety requirements of the operation, the Granta cobot palletiser can be used with or without guarding, offering flexibility in its implementation.

Merits of Cobot Box Palletisers:

  1. Safety and Collaboration: The Granta cobot is equipped with intelligent force sensing, enabling it to operate safely alongside human workers. In collaborative mode, the cobot runs at reduced speeds and can detect unexpected forces, stopping immediately if an obstruction is encountered. This feature ensures a safe working environment and reduces the risk of injury.
  2. Enhanced Productivity: When operating in industrial robot mode—where full safety measures are in place and no personnel are within the safe zone—the cobot can run at full speed, significantly increasing palletising efficiency. This dual-mode operation allows businesses to maximise productivity while maintaining a high standard of safety.
  3. Adaptability: The cobot’s ability to switch between collaborative and industrial modes makes it highly adaptable to different production environments. Whether working alongside human operators or handling tasks autonomously, the Granta system can easily adjust to meet varying operational needs.
  4. Ease of Use: With its user-friendly programming software and quick installation process, the Granta cobot palletiser is designed to be accessible and straightforward to use, even for operators with no experience in automation.

Compact Palletisers:

Compact palletisers are designed to deliver high-performance palletising in environments where space is at a premium. These systems are ideal for applications that require the power of an industrial robot but also need to accommodate space constraints and allow for pallet truck access. The compact palletiser system excels in such scenarios, offering a blend of efficiency, speed, and ease of use.

Key Features of the Compact Palletiser System:

  1. Pallet Truck Take-Off: The system is specifically designed to allow pallets to be removed using a pallet truck, making it convenient for operations where forklift access might be limited or where quick pallet removal is necessary.
  2. Space-Efficient Design: As the name suggests, the compact palletiser is built to occupy minimal floor space while still providing robust palletising capabilities. Its design allows for integration into production lines where every square foot counts.
  3. Low Profile Conveyors: The inclusion of low-profile conveyors ensures smooth and efficient movement of boxes through the palletising process without requiring excessive vertical space, further enhancing the system’s compact nature.
  4. 120kg Payload Robot: The system is equipped with a powerful robot capable of handling payloads up to 120kg, making it suitable for a wide range of box sizes and weights. This high payload also enables the robot to pick multiple products at a time which further enhances the speeds and cycle time.
  5. Variety of Gripper Options: A selection of grippers is available to suit different types of boxes and packaging materials, providing flexibility for diverse palletising applications.
  6. Quick Installation: The compact palletiser is designed for fast and straightforward installation, allowing businesses to quickly implement the system and start reaping its benefits without significant downtime.

Merits of the Compact Palletiser System:

  1. Optimised for High-Speed Lines: Despite its small footprint, the compact palletiser is capable of high-speed operation, making it an ideal solution for production lines that require quick and efficient palletising. The system can also include row gripping capabilities if needed, further enhancing its speed and efficiency.
  2. Automated Pallet and Slip Sheet Handling: The system can be configured to include automated pallet feeding and slip sheet placement, which helps streamline the palletising process and reduces the need for manual intervention. This automation is particularly beneficial in high-throughput environments where speed and consistency are critical.
  3. User-Friendly Operation: The compact palletiser features easy-to-use programming software, enabling operators to set up and modify palletising tasks with minimal effort. This user-friendly interface reduces the learning curve and ensures that the system can be operated effectively with limited training.
  4. Space-Saving Efficiency: The compact design of this palletiser does not compromise its capabilities. It is specifically engineered to deliver high-speed, efficient palletising in a small footprint, making it perfect for facilities with limited space.

Modular Palletising Systems:

The modular palletiser system is a highly adaptable solution, designed to meet the diverse needs of today’s industries. It offers unparalleled flexibility and ease of use, making it suitable for a wide range of palletising applications, from standard pick-and-place tasks to more complex high-speed layer forming.

Key Features of the Modular Palletiser System:

  1. User-Friendly Programming: The system is designed for fast and straightforward programming, eliminating the need for specialist skills. Operators can quickly set up palletising tasks, making it an accessible option for facilities of all sizes.
  2. Automatic Stack Generation: With automatic stack generation available at the touch of a button, the system can handle an infinite variety of products, pallets, and stack configurations. This feature is particularly valuable for businesses that deal with a wide range of product sizes and types.
  3. 120kg Payload Robot: The system is equipped with a powerful robot capable of handling payloads up to 120kg, making it suitable for a wide range of box sizes and weights. This high payload also enables the robot to pick multiple products at a time which further enhances the speeds and cycle time.
  4. Versatile Applications: The modular palletiser is capable of handling everything from standard pick-and-place palletising of bags or boxes to high-speed layer forming. It’s also equipped to handle automated container unloading and palletising, expanding its utility across various tasks.
  5. Fully Automated Programming: For operations that frequently change the sizes and types of products being palletised, the system offers a fully automated programming option. This feature allows for the automatic setup of pallet stack patterns and robot programming, significantly reducing setup time and enhancing operational efficiency.
  6. Reconfigurable Design: The modular nature of the system means it can be easily and quickly reconfigured to meet changing production requirements. This adaptability ensures that the system remains relevant and effective as business needs evolve.

Merits of the Modular Palletiser System:

  1. Flexibility and Adaptability: The modular design allows businesses to easily reconfigure the system as their production needs change. The system can be quickly adapted without major disruptions to scale with and adapt to your company needs in the future.
  2. Quick Installation and Short Lead Times: Thanks to its modular construction, the palletiser can be delivered and installed with minimal lead time. This rapid deployment helps businesses start improving their palletising processes sooner, reducing downtime and increasing efficiency.
  3. Efficiency Across Multiple Applications: Whether handling standard boxes, bags, or more complex palletising configurations, the system’s versatility ensures it can meet a wide range of needs. This makes it a valuable investment for businesses looking to streamline their operations across different products and tasks. Multiple lines can be palletised by one system.

These advanced palletising systems can all be tailored to meet our specific needs—whether it’s maximising space with a compact palletiser, improving flexibility and safety with a cobot system, or achieving adaptability and efficiency with a modular palletiser. As the industry continues to evolve, the integration of these innovative technologies will be key to maintaining competitive advantage and operational excellence.

If you would like to know more about the Granta Compact Palletising systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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What Palletiser Is Best For The Pet Food Industry?

Posted on August 9, 2024 by Granta

The pet food industry is one of the fastest-growing and most competitive markets today, fueled by a surge in pet ownership and an increasing demand for premium, convenient products. To keep pace with this growth, manufacturers must optimise every aspect of their operations, particularly in packaging and logistics. One critical element in this process is palletising—stacking products onto pallets for efficient storage and shipment. The right palletiser can make a substantial difference, directly impacting productivity, cost-efficiency, and product safety. In this article, we’ll delve into the key factors to consider when selecting a palletiser for the pet food industry and explore the various options available to meet these specific needs.

Key Considerations for Palletisers in the Pet Food Industry

  1. Product Variability and Packaging Types
    The pet food industry deals with a wide range of packaging formats, from heavy bags and sacks to delicate cans, pouches, and cartons. Each of these packaging types has distinct handling requirements:
    • Bags and sacks: These are often bulky and heavy, demanding a palletiser that can handle the weight with care to prevent damage.
    • Cans and pouches: These need precise stacking to avoid crushing and maintain stability throughout the supply chain.
    • Cartons: These typically require high-speed handling without compromising the structural integrity of the packaging.
  2. Speed and Throughput Requirements
    In a high-demand market like pet food, manufacturers often operate large-scale, high-speed production lines. The palletiser must keep pace, handling large volumes quickly and efficiently, without creating bottlenecks. This includes the ability to process multiple product lines simultaneously, ensuring that production output meets market demand.
  3. Flexibility and Adaptability
    The pet food market is continually evolving, with new product sizes, packaging types, and pallet configurations frequently introduced. A palletiser with the capability for quick changeovers and easy programming is invaluable, offering manufacturers the agility to adapt to changing production requirements without losing efficiency.
  4. Footprint and Space Constraints
    Manufacturing facilities are often packed with various pieces of equipment, making space a critical consideration. The ideal palletiser should have a compact footprint, or be designed for integration into existing layouts without necessitating extensive reconfigurations. This not only maximises available space but also minimises disruption to production.
  5. Cost and ROI
    Investing in a palletiser is a significant financial commitment. It’s essential to consider the total cost of ownership, which includes not just the purchase price, but also ongoing maintenance, energy consumption, and operational efficiency. A well-chosen palletiser should offer a strong balance between upfront cost and long-term performance, delivering a reasonable return on investment (ROI) while boosting overall productivity.

Types of Palletisers for the Pet Food Industry

Understanding the different types of palletiser available is crucial, as each type offers unique strengths and applications. Here’s an overview of the leading types of palletisers that cater to the specific needs of this industry:

  1. Modular Robotic Palletisers
    Modular robotic palletisers are known for their high flexibility and efficiency, whilst their easy programming software ensures quick setup and adaptability. These systems use robotic arms to pick and place products onto pallets with precision. They are ideal for handling a variety of packaging types, including heavy bags, cans, and cartons, commonly used in the pet food industry. Their modular design allows easy adaptation to different production setups, and their compact footprint makes them suitable for facilities with limited space. These palletisers are capable of high-speed operation and can be programmed to manage multiple product lines, making them versatile for various palletising needs.
  2. Compact Robotic Palletiser
    The compact palletiser system is an ideal solution for the pet food industry, particularly in environments where space is at a premium and efficient pallet handling is essential. Its compact design, combined with a robust 120kg payload robot, allows it to handle a variety of packaging types with ease. The system’s low-profile conveyors and pallet truck take-off feature enable seamless integration into tight spaces, while the easy programming software ensures quick setup and adaptability. With options for different grippers, row gripping, and the inclusion of slipsheets and auto pallet feeding, this system provides high-speed, efficient palletising that maximises productivity without sacrificing valuable floor space.
  3. Cobot Palletiser
    The cobot palletising system is particularly well-suited for the pet food industry, offering a versatile and safe solution for lightweight palletising tasks. Its advanced 30kg payload collaborative robot can operate in both collaborative mode, working safely alongside human workers, and in industrial robot mode, maximising speed and efficiency when the area is secured. This dual functionality ensures that the system can adapt to different production needs while maintaining high safety standards. With its easy programming, robust design for 24/7 use, and quick installation, the cobot palletiser enhances productivity while providing the flexibility needed in a dynamic manufacturing environment.

Each type of palletiser offers specific advantages and is suited to different operational needs within the pet food industry. The choice of palletiser will depend on factors such as the type of packaging, production speed requirements, available space, and the level of automation desired.

Conclusion

In summary, choosing the right palletiser for the pet food industry is not just about handling products—it’s about ensuring that every aspect of production and logistics operates smoothly and efficiently. From handling a variety of packaging types to meeting high-speed demands and maintaining hygiene, the ideal palletiser is a cornerstone of a successful pet food manufacturing operation.

If you would like to know more about the Granta palletising systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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The Compact Palletiser: A Space-Saving Solution for Efficient Palletising

Posted on August 7, 2024 by Granta

In the fast-paced world of food and beverage production, efficiency is paramount. As companies strive to meet increasing demand while maintaining quality and safety standards, the need for advanced, space-efficient palletising solutions has never been greater. Enter the Compact Palletiser—an innovative system designed to meet the demands of high-speed production lines while accommodating spatial constraints and the need for pallet truck take-off.

Key Features of the Compact Palletiser

The Compact Palletiser is a meticulously engineered solution that brings a host of powerful features to your production line:

  • Pallet Truck Take-Off: One of the defining features of the Compact Palletiser is its ability to seamlessly integrate with pallet trucks, allowing for the smooth and efficient removal of full pallets. This design not only reduces the need for complex handling equipment but also ensures that your production line keeps moving without unnecessary interruptions.
  • Space-Efficient Design: In many production environments, space is a critical concern. The Compact Palletiser’s design addresses this by offering a minimal footprint, allowing you to fit the system into tight spaces without sacrificing functionality or performance. This compactness is particularly beneficial for facilities looking to expand operations without a costly overhaul of their existing floor plan.
  • Low Profile Conveyors: The inclusion of low profile conveyors is a game changer, as it facilitates the easy movement of products and pallets through the system. These conveyors are designed so that they can be loaded and unloaded using either a fork lift truck or a pallet truck.
  • User-Friendly Programming: The system’s programming software is designed with ease of use in mind. Even operators with minimal technical experience can quickly learn to program and operate the Compact Palletiser, reducing the need for extensive training and minimising operator error. This intuitive interface also allows for quick adjustments, ensuring that you can adapt to changing production needs with minimal downtime.
  • 120kg Payload Robot: At the heart of the Compact Palletiser is a powerful industrial robot capable of handling a wide range of products, from lightweight packages to heavier, bulkier items. This versatility ensures that the system can be tailored to suit the specific demands of your production line, whether you’re palletising fragile goods or heavy cases.
  • Variety of Gripper Options: The ability to customise the system with different gripper configurations means that the Compact Palletiser can handle an array of product shapes and sizes. This flexibility is crucial in the food and beverage industry, where packaging types can vary widely depending on the product.
  • Quick Installation: Speed is of the essence when upgrading production lines, and the Compact Palletiser is designed for rapid installation. This feature means you can minimise production downtime during setup, allowing your operations to return to full capacity swiftly.
  • Adaptable for High-Speed Production Lines: One of the most significant benefits of the Compact Palletiser is its versatility. It’s not just a one-size-fits-all solution but a system that can be adapted to meet the specific demands of high-speed production lines in the food and beverage industry. Whether you require features like row gripping for delicate handling, slip sheet placement, or automated pallet feeding, the Compact Palletiser can be configured to meet these needs. This adaptability ensures that your investment in palletising technology can grow and evolve alongside your business, keeping pace with changes in production volume and packaging types.

Configurations of the Compact Palletiser System

The Compact Palletiser system is available in three distinct configurations, each tailored to different levels of automation and operational complexity:

  1. Compact Palletiser Static
    • Overview: The Static model is the entry-level option within the Compact Palletiser range. It allows for the loading of a single new pallet while the robot continues its operation. Full pallets are removed manually through a gate, making it ideal for slower speed operations that demand efficiency and reliability.
    • Operation: Available in both single and double lane configurations, the system pauses when full pallets are removed, ensuring a controlled and safe operation. Full pallets can be taken off using either a pallet truck or forklift, depending on your facility’s equipment.
  2. Compact Palletiser Auto
    • Overview: The Auto model enhances the efficiency of the palletising process by incorporating low profile conveyors that transport finished pallets out of the cell, allowing the robot to continue its work uninterrupted. This configuration is perfect for operations that require continuous palletising without manual stops, thereby increasing overall throughput.
    • Operation: This system is available in single or double lane configurations, offering flexibility to match your production line’s needs. The seamless integration with pallet trucks or forklifts for pallet removal ensures that the production flow is maintained at all times.
  3. Compact Palletiser Auto with Pallet Feeder
    • Overview: The most advanced option in the Compact Palletiser range, this system is designed for fully automated operation. It features an automatic pallet feeder that ensures a constant supply of empty pallets, enabling the robot to operate continuously without the need for manual intervention. This model is ideal for high-capacity production lines where uptime is critical.
    • Operation: This configuration supports both single and double lane systems, with a low-profile input on the pallet feeder for easy loading of empty pallets using pallet trucks or forklifts. Finished pallets are automatically transported out of the cell, creating a smooth and efficient workflow that minimises downtime and maximises productivity.

Enhancing Your Palletising Process with the Compact Palletiser

The Compact Palletiser is more than just a space-saving solution; it’s a versatile, efficient, and scalable system designed to meet the evolving needs of the food and beverage industry. Whether you’re looking to streamline operations, increase output, or simply make better use of your available space, the Compact Palletiser offers a range of configurations and features that can be tailored to your specific needs.

Investing in the Compact Palletiser means investing in a future-proof solution that enhances your production capabilities while providing the flexibility to grow and adapt as your business evolves. With its combination of robust design, user-friendly operation, and advanced automation options, the Compact Palletiser is poised to become an indispensable asset in your production line, helping you achieve greater efficiency and success in a competitive market.

If you would like to know more about the Granta Compact Palletising systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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Strategic Cost Management for Manufacturing Managers

Posted on August 2, 2024 by Granta

In the manufacturing industry, managing costs effectively is paramount to sustaining profitability and competitiveness. Managers are continually challenged to find ways to reduce costs without sacrificing quality while also ensuring that investments yield the highest possible returns. This article looks into two critical aspects of cost management: cost reduction strategies and ROI optimisation.

Cost Reduction Strategies: Identifying Ways to Reduce Costs Without Compromising Quality

Reducing costs while maintaining, or even improving, product quality requires a strategic and multifaceted approach. Here are several proven strategies that can be implemented:

  1. Lean Manufacturing:
    • Eliminate Waste: Identify and eliminate waste in all forms—overproduction, waiting times, excess inventory, unnecessary motion, defects, over-processing, and underutilised talent. Techniques such as value stream mapping can help pinpoint inefficiencies, streamline operations, and enhance productivity.
    • Continuous Improvement (Kaizen): Foster a culture of continuous improvement where employees at all levels are encouraged to suggest and implement incremental improvements. This approach not only leads to significant cost savings but also boosts employee engagement and innovation.
  2. Supply Chain Optimisation:
    • Supplier Partnerships: Develop strong relationships with suppliers to negotiate better pricing, improve supply chain reliability, and reduce lead times. Collaborative planning, forecasting, and replenishment (CPFR) can enhance inventory management and reduce costs associated with stockouts or excess inventory.
    • Bulk Purchasing: Take advantage of bulk purchasing discounts and consolidate orders to reduce shipping and handling costs. Additionally, implementing vendor-managed inventory (VMI) systems can further streamline the supply chain.
  3. Technology and Automation:
    • Invest in Automation: Automate repetitive and labour-intensive tasks to reduce labour costs, increase production speed, and improve precision. Robotics, AI, and IoT technologies can significantly enhance operational efficiency, reduce errors, and minimize waste.
    • Adopt Advanced Manufacturing Technologies: Implement technologies such as 3D printing, CNC machining, and advanced robotics to streamline production processes and reduce material waste. These technologies can also enable more flexible and customized manufacturing capabilities.
  4. Energy Efficiency:
    • Conduct Energy Audits: Regularly assess energy use and identify areas where efficiency can be improved. Upgrading to energy-efficient machinery, optimising facility layouts, and implementing energy management systems can result in substantial energy savings and reduced operational costs.
    • Utilise Renewable Energy: Invest in renewable energy sources such as solar or wind power to reduce long-term energy costs and enhance sustainability. Government incentives and rebates can also offset some of the initial investment costs.
  5. Workforce Training and Development:
    • Employee Training: Invest in comprehensive training programs to enhance employee skills, productivity, and safety. Well-trained employees can operate machinery more efficiently, reduce error rates, and contribute to process improvements.
    • Cross-Training: Cross-train employees to perform multiple roles. This approach reduces downtime caused by absences, improves workforce flexibility, and ensures that critical operations can continue seamlessly.
  6. Effective Inventory Management:
    • Just-in-Time (JIT) Inventory: Implement JIT inventory systems to reduce inventory holding costs and minimise waste. This approach aligns inventory levels closely with production schedules and demand forecasts, reducing the risk of overproduction and obsolescence.
    • Inventory Analysis: Use ABC analysis to categorize inventory based on importance and turnover rates, allowing for better inventory control and reduced carrying costs. Additionally, implementing automated inventory management systems can provide real-time visibility and optimisation.

ROI Optimisation: Ensuring Investments Yield the Highest Possible Returns

Maximising the return on investment (ROI) is crucial for justifying capital expenditures and ensuring long-term financial health. Here’s some strategies that can be implemented to optimise ROI:

  1. Thorough Feasibility Studies:
    • Conduct comprehensive feasibility studies before making any investment. Analyse market trends, competitive landscape, technological advancements, and financial projections to ensure the investment aligns with strategic objectives and has a high likelihood of success. Engaging cross-functional teams in these studies can provide diverse insights and improve decision-making.
  2. Clear Performance Metrics:
    • Establish clear performance metrics and key performance indicators (KPIs) to measure the success of investments. Metrics such as payback period, net present value (NPV), internal rate of return (IRR), and total cost of ownership (TCO) are essential for evaluating investment performance. Regular monitoring and reporting on these metrics ensure transparency and accountability.
  3. Project Prioritisation:
    • Prioritise projects based on their potential ROI and strategic importance. Focus on initiatives that align with long-term goals, enhance competitive advantage, and offer the most significant financial benefits. This strategic prioritisation ensures that limited resources are allocated to the most impactful projects, maximising overall returns.
  4. Continuous Monitoring and Improvement:
    • Implement a system for continuous monitoring of investments. Regularly review performance data to identify underperforming assets and make necessary adjustments. This proactive approach ensures investments remain on track to deliver expected returns and allows for agile responses to changing market conditions.
  5. Risk Management:
    • Develop a robust risk management strategy to mitigate potential risks associated with investments. Conduct risk assessments, scenario planning, and sensitivity analysis to prepare for uncertainties and minimise potential losses. Establishing contingency plans and risk mitigation measures can safeguard investments and ensure smoother project execution.
  6. Post-Investment Analysis:
    • Conduct post-investment reviews to evaluate the actual performance of investments against initial projections. Identify lessons learned and apply them to future investment decisions. This feedback loop helps refine investment strategies, improve future outcomes, and build a knowledge base for better decision-making.

In a constantly evolving industry, staying agile and forward-thinking is key. Embracing these cost management strategies will enable you to navigate challenges, capitalise on opportunities, and secure a competitive edge in the market. By fostering a culture of continuous improvement, leveraging advanced technologies, and prioritising strategic investments, you can drive sustainable success and growth in an increasingly competitive landscape.

If you would like to know more about the Granta palletising systems or AMR/AGV systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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How to Reduce Labour Costs in Palletising

Posted on July 24, 2024 by Granta

Palletising, the process of stacking products onto pallets for storage or shipping, is a crucial aspect of many industries, including manufacturing, logistics, and retail. However, manual palletising can be labour-intensive, time-consuming, and prone to errors, leading to increased labour costs and reduced efficiency. Reducing these costs while maintaining or improving productivity is essential for businesses to stay competitive. Here are several strategies to achieve this:

1. Implement Automated Palletising Systems

Robotic Palletisers: Investing in robotic palletisers can significantly reduce labour costs. These machines can handle repetitive tasks with high accuracy and consistency, reducing the need for manual labour. Robotic arms equipped with advanced grippers can handle various product shapes and sizes, improving overall efficiency. Additionally, robotic palletisers can operate continuously without fatigue, leading to increased throughput and reliability.

Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs): AGVs/AMRs can transport pallets within the facility, reducing the need for human-operated forklifts. They can be programmed to follow specific paths, ensuring timely and efficient pallet movement. This not only reduces labour costs but also enhances safety by minimising human interaction with heavy machinery.

2. Enhance Workflow Efficiency

Optimise Layout: Analyse the layout of your palletising area to minimise unnecessary movement and handling. Ensure that products, pallets, and equipment are strategically placed to streamline the palletising process. A well-designed layout can significantly reduce the time and effort required for palletising, leading to lower labour costs and increased productivity.

Lean Manufacturing Principles: Implement lean manufacturing principles to eliminate waste and improve efficiency. Techniques such as 5S (Sort, Set in order, Shine, Standardise, Sustain) can help organise the workspace and reduce time spent on non-value-added activities. Lean practices can also uncover hidden inefficiencies and opportunities for improvement.

Standard Operating Procedures (SOPs): Develop and enforce SOPs for palletising tasks. Clear guidelines and training can help workers perform their tasks more efficiently and consistently. SOPs also ensure that best practices are followed, reducing errors and enhancing overall productivity.

3. Invest in Ergonomic Solutions

Ergonomic Tools: Provide workers with ergonomic tools such as lift-assist devices, pallet jacks, and adjustable height workstations. These tools can reduce physical strain and fatigue, improving productivity and reducing the risk of injuries. Ergonomic solutions not only enhance worker comfort but also lead to fewer work-related injuries and associated costs.

Training Programs: Conduct regular training programs on proper lifting techniques and the use of ergonomic equipment. Educated workers are less likely to experience work-related injuries, leading to fewer lost workdays and lower labour costs. Continuous education on ergonomics can foster a culture of safety and efficiency.

4. Utilise Data and Analytics

Performance Monitoring: Implement systems to monitor and analyse the performance of your palletising operations. Data on cycle times, error rates, and downtime can help identify bottlenecks and areas for improvement. Performance data can enable quick decision-making and adjustments to maintain optimal productivity.

Preventative Maintenance: Regular preventative maintenance can reduce unexpected downtime and maintain smooth operations. Proactive maintenance ensures that machinery operates efficiently, extending its lifespan and reducing long-term costs.

5. Adopt Flexible Staffing Strategies

Cross-Training Employees: Cross-train employees to perform palletising. This flexibility allows you to allocate labour more efficiently based on workload demands. Cross-trained employees can adapt to different roles, reducing the need for additional hires and ensuring operational continuity.

Temporary Staffing: During peak periods, consider hiring temporary workers to handle increased demand. This approach can help manage labour costs by scaling the workforce up or down as needed. Temporary staffing provides the agility to respond to market fluctuations without long-term labour commitments.

6. Leverage Technology for Process Improvement

Warehouse Management Systems (WMS): Implement a WMS to optimise inventory management and order fulfilment processes. A WMS can streamline the palletising process by ensuring that the right products are available at the right time. This reduces delays and improves the efficiency of the entire supply chain.

Palletising Software: Use specialised palletising software to design optimal pallet patterns and configurations. Efficient stacking patterns can maximise space utilization and reduce the number of pallets needed, leading to cost savings. Palletising software can also simulate different scenarios to find the most efficient loading strategies.

By implementing these strategies, businesses can improve productivity, enhance worker safety, and ultimately reduce labour costs, leading to a more efficient and competitive operation. Investing in modern palletising solutions not only cuts costs but also positions businesses for long-term success in a rapidly evolving marketplace.

If you would like to know more about the Granta palletising systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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Asset Management in Manufacturing: Lifecycle Management and Maintenance Planning

Posted on July 16, 2024 by Granta

In the competitive and dynamic landscape of manufacturing, efficient asset management is essential for maintaining operational efficiency, enhancing productivity, and driving profitability. Capex managers are at the forefront of this effort, responsible for overseeing the lifecycle of assets from acquisition to disposal and devising effective maintenance strategies to ensure equipment reliability and longevity. This article explores the critical aspects of asset management, focusing on lifecycle management and maintenance planning, and provides actionable insights for capex managers in the manufacturing sector.

Lifecycle Management: From Acquisition to Disposal

1. Asset Acquisition:

  • Needs Assessment: The initial phase of asset management involves a comprehensive needs assessment to identify the necessity for new equipment or machinery. This includes a detailed analysis of current operational capabilities, pinpointing gaps or inefficiencies, and determining the specific requirements for new assets.
  • Vendor Selection: Selecting the right vendor is a critical decision that can significantly impact the long-term performance and cost-effectiveness of assets. Capex managers should evaluate potential vendors based on their reputation, reliability, cost, after-sales support, and the quality of their products.
  • Total Cost of Ownership (TCO): It is essential to consider the total cost of ownership rather than just the initial purchase price. TCO includes maintenance, operating costs, energy consumption, downtime costs, and the expected lifespan of the asset. A thorough TCO analysis ensures a more informed and financially sound acquisition decision.

2. Asset Utilisation:

  • Optimal Deployment: Once acquired, assets must be deployed strategically to maximise their usefulness and integrate seamlessly into the manufacturing process. This involves careful planning of asset placement and ensuring that operators are well-trained and capable of using the equipment efficiently.
  • Performance Monitoring: Regular and systematic monitoring of asset performance is crucial. Key performance indicators (KPIs) such as uptime, throughput, efficiency, and quality metrics should be tracked. Advanced analytics can be used to interpret these KPIs and provide actionable insights for continuous improvement.

3. Maintenance and Upgrades:

  • Scheduled Maintenance: Implementing a routine maintenance schedule is vital for ensuring that assets operate at peak efficiency and reducing the likelihood of unexpected breakdowns. Maintenance activities should be planned and executed based on the manufacturer’s recommendations and operational requirements.
  • Technological Upgrades: Periodically upgrading assets with the latest technology can significantly enhance performance and extend their useful life. This may include software updates, hardware enhancements, or retrofitting existing machinery with advanced components to improve functionality and efficiency.

4. Asset Disposal:

  • End-of-Life Assessment: When an asset reaches the end of its useful life, a thorough assessment should be conducted to determine whether it should be refurbished, repurposed, or disposed of. Factors such as the asset’s condition, technological relevance, and potential resale value should be considered.
  • Sustainable Disposal: Environmentally responsible disposal methods should be prioritised to minimise the environmental impact. This includes recycling, donating equipment to educational institutions or non-profits, and ensuring compliance with environmental regulations.

Maintenance Planning: Ensuring Optimal Performance and Longevity

Effective maintenance planning is a cornerstone of asset management, ensuring that equipment remains operational and efficient throughout its lifecycle.

1. Preventive Maintenance:

  • Regular Inspections: Conducting regular inspections helps identify potential issues before they result in equipment failure. This includes routine checks of critical components and systems, ensuring that they are in good working condition and any signs of wear or damage are addressed promptly.
  • Scheduled Servicing: Adhering to a manufacturer-recommended service schedule helps maintain the reliability and efficiency of assets. Scheduled servicing activities include lubrication, calibration, part replacements, and other routine maintenance tasks that prevent equipment deterioration and extend its operational life.

2. Predictive Maintenance:

  • Condition Monitoring: Utilising sensors and technology to monitor the real-time condition of assets can predict potential failures. Depending on the type of asset, parameters such as vibration, temperature, and noise levels can be continuously monitored to detect anomalies that may indicate impending issues.
  • Data Analytics: Leveraging advanced data analytics to interpret condition monitoring data provides deep insights into asset health. Predictive maintenance models can forecast maintenance needs, allowing for timely interventions and reducing unplanned downtime.

3. Corrective Maintenance:

  • Root Cause Analysis: When equipment failures occur, performing a root cause analysis is essential to understand the underlying issues and prevent recurrence. This involves a systematic investigation to identify the cause of failure and implement corrective actions.
  • Timely Repairs: Promptly addressing identified issues through corrective maintenance minimises downtime and prevents further damage to the equipment. Quick and effective repairs restore the equipment to optimal working condition and maintain production continuity.

4. Maintenance Management Systems:

  • Computerised Maintenance Management System (CMMS): Implementing a CMMS can streamline maintenance activities by automating scheduling, tracking work orders, and managing spare parts inventory. A CMMS improves maintenance efficiency, reduces administrative burdens, and enhances asset performance tracking.
  • Integration with ERP: Integrating maintenance management with enterprise resource planning (ERP) systems provides a comprehensive view of asset performance, maintenance costs, and overall operational efficiency. This holistic approach aids in better decision-making and resource allocation.

By adopting a structured approach to managing assets from acquisition to disposal and implementing robust maintenance strategies, you can achieve optimal performance, reduce downtime, and extend the lifespan of their equipment. This not only enhances operational efficiency but also contributes to the overall financial health and sustainability of the manufacturing operation. Embracing technological advancements and integrating data-driven insights into asset management practices will empower you to drive continuous improvement and maintain a competitive edge in the industry.

If you would like to know more about the Granta palletising systems or AMR/AGV systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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Ways To Speed Up The Palletising Process In Production

Posted on July 15, 2024 by Granta

Optimising the palletising process in production is crucial for enhancing overall efficiency, reducing operational costs, and maintaining a smooth workflow. In today’s competitive manufacturing environment, speeding up palletising not only boosts productivity but also improves product handling and distribution. This article outlines a range of specific strategies and technologies designed to significantly accelerate the palletising process, from advanced equipment and software solutions to ergonomic enhancements and lean manufacturing techniques. By implementing these targeted approaches, manufacturers can achieve faster, more reliable palletising operations, ultimately contributing to a more efficient and profitable production line.

1. Palletising Equipment

  • Robotic Palletisers: Invest in a robotic palletiser suitable for your production volumes and product types. Even entry-level models can handle multiple SKUs and configurations if they have easy programming software. These robots can work continuously without fatigue, maintaining high precision and consistency in palletising tasks, which significantly enhances overall productivity.
  • Layer Forming Palletisers: If your production is high speed, then consider using layer forming palletisers that can form and place entire layers of products on a pallet in one motion. This approach drastically reduces the time needed compared to placing individual items and is particularly effective for uniform product sizes and shapes.

2. Conveyor Integration

  • Infeed Conveyors: Implement high-speed infeed conveyors to deliver products swiftly to the palletising area. Ensure that the conveyor system is fully synchronised with the palletiser to prevent bottlenecks. The use of conveyors minimises manual handling, reducing labour costs and speeding up the process.
  • Accumulation Conveyors: Utilise accumulation/buffering conveyors to create a buffer of products ready for palletising. This ensures a steady and continuous supply, allowing the palletiser to operate at maximum efficiency without waiting for the next batch of products.

3. Pallet Pattern Optimization

  • Pattern Forming Software: Utilise advanced pallet pattern optimisation software to design the most efficient loading patterns. This will be included as standard on a good palletising system and it will automatically calculate optimal stacking patterns, ensuring maximum pallet stability and efficient use of space. This reduces the number of cycles needed and minimises the risk of pallet collapse during transportation.
  • Easy Programming Software: If you are palletising multiple sizes of product off the production line, it is essential to ensure that the system has easy programming software. This will enable staff to quickly reprogram the palletiser for new product sizes. This adaptability can significantly improve throughput by reducing the need to wait for an experienced robot programmer to set up a new stack pattern.

4. End-of-Arm Tooling (EOAT) Enhancements

  • Multi-Pick EOAT: Equip robotic arms with end-of-arm tooling capable of picking up multiple items simultaneously – such as row gripping or layer forming. This feature reduces the number of cycles required to complete a pallet, thereby speeding up the entire palletising process.
  • Adjustable Grippers: Invest in EOAT with adjustable grippers to handle a variety of product shapes and sizes without the need for manual changeovers. This versatility is crucial for operations handling multiple SKUs, as it allows for quick transitions between different products without downtime.

5. Automated Stretch Wrapping

  • Integrated Stretch Wrappers: Position automatic stretch wrappers directly at the end of the palletising line. By integrating stretch wrapping into the palletising process, pallets are wrapped immediately after they are formed, ensuring stability and reducing the need for additional manual handling. This seamless integration enhances overall efficiency and protects products during transport.
  • Pre-Stretch Film: Utilise pre-stretch film in the wrapping process to enhance load stability while using less material. Pre-stretch film can stretch up to 250% before application, providing better coverage and load containment, which is essential for secure and stable pallets.

6. Monitoring and Preventative Maintenance

  • Production Monitoring: Implement production monitoring systems to provide monitoring and control of the palletising process. This information will enable you to maintain efficiency, reduce downtime, and achieve higher product standards.
  • Preventative maintenance: Ensure your equipment has a contract that includes regular service visits to ensure the equipment is maintained in good working order.

7. Operator Training and SOPs

  • Standard Operating Procedures (SOPs): Develop comprehensive SOPs for all palletising tasks and ensure that all operators are trained to follow them. Clear and detailed SOPs help in standardising the process, reducing variability, and improving efficiency.
  • Continuous Training Programs: Establish ongoing training programs to keep operators updated on the latest best practices, technologies, and safety protocols. Regular training ensures that operators are skilled and confident in using advanced equipment and following optimised procedures.

8. Lean Manufacturing Techniques

  • Value Stream Mapping: Conduct value stream mapping specifically for the palletising process to identify and eliminate waste. This technique helps in visualising the entire process, pinpointing inefficiencies, and implementing targeted improvements. AMRs or AGVs can be used to ensure that the palletising system never has to stop and wait for pallets to be removed from the system.
  • Kaizen Events: Organise regular Kaizen events focused on incremental improvements in the palletising area. These events encourage continuous improvement through collaborative efforts and can lead to significant enhancements in efficiency and productivity over time.

As you can see, there are many different strategies that can be implemented to speed up the palletising process in production.  Not all of these may be applicable to your production environment, but implementing any of these strategies will ultimately enhance the speed and efficiency of your palletising process; leading to increased productivity, reduced operational costs, improved overall workflow, and a more competitive edge in the market.

If you would like to know more about the Granta palletising systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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How To Automate Cross Palletising and Depalletising from UK to Euro Pallets

Posted on July 11, 2024 by Granta

Cross palletising of product from Euro to UK pallets, or UK to CHEP pallets, is a task that is becoming more frequently required than ever before. With the advances in robotic systems and easy programming software, automating this process has now become a very viable option, resulting in enhanced productivity, reduced labour costs, and eliminating human error.

Understanding The Implications of Repalletising

Before diving into the robotic system and how it works, it is important to understand the implications of transferring from one pallet type to another. The difference in pallet size means that products must be rearranged and restacked, usually in a different stack pattern, to fit onto the new pallet.  This means that depending on the layout of the goods, they may be able to be removed in multiples, or they may need to be removed individually.

How do Robotic Systems Cross Palletise and Depalletise Product

In essence, a robotic system will pick product form one pallet and place it onto another, however, below is a more detailed explanation of how such a system typically operates:

  1. Detection and Analysis:
  • The system is programmed for the product size that is being depalletised and the correct stack pattern for repalletising on the destination pallet is selected.  With easy programming software on the palletiser this is very quick and easy to do.
  • If required the system can also use advanced sensors, cameras, and detection tools to scan and pinpoint the exact layout and positioning of items on the source pallet.
  • Utilising sophisticated software algorithms, it analyses the gathered data to determine the optimal sequence and method for efficiently picking up each item
  1. Depalletising:
  • The robotic arm selects and securely grips each item on the source pallet. Typically, a vacuum gripper would be used, but other gripper types may be used depending on the product type.
  • The robotic arm then lifts each item from the source pallet with precision. Depending on the nature and layout of the product being depalletised, product may be lifted individually or in multiples.
  • An angled alignment frame or conveyor system may be used to ensure the product is accurately re-positioned prior to repalletising onto the new pallet.
  1. Repalletising:
  • The robotic arm then moves each item (or multiples of items) from the source pallet to the destination pallet. Items are then strategically placed onto the destination pallet in the pre-selected stack pattern.
  • This process is then repeated until all of the items on the source pallet have been successfully transferred.

Products best suited to automated depalletising systems

Some products are better suited to automated depalletising than others.  Below is a list of product types that typically work well on automated depalletising and repalletising systems.

  1. Cartons and Boxes: Automated systems can be efficiently used to depalletise cartons and boxes of various sizes and weights. This is commonly used in distribution centres, and e-commerce warehouses. A vacuum gripper is typically used for this task.
  2. Bottles and Containers: Automated systems can be used to depalletise bottles, jars, cans, and containers in industries such as food and beverage and pharmaceuticals. A bespoke gripper would typically be used for this, and it would be designed to specifically suit the type of bottle/container being depalletised.
  3. Palletised Drums: Industries dealing with chemicals and oils use automatic depalletisation for handling palletised drums. A barrel gripper with two clamping arms is typically employed for secure handling of drums and barrels.

Key Benefits of Using Robotic Systems for Depalletising and Cross Palletising

There are many different benefits of using an automated system for depalletising and cross stacking of pallets.  Listed below are some of the key benefits.

  1. Increased Efficiency: Robotic systems operate continuously and can handle high volumes of pallets with minimal downtime.
  2. Enhanced Precision: Advanced vision systems and precise robotic arms ensure accurate handling and stacking of products, reducing the risk of damage.
  3. Cost Savings: Automation reduces labour costs associated with manual palletising and depalletising tasks.
  4. Scalability: Robotic systems can be scaled up or down based on the facility’s needs, making them suitable for operations of all sizes.
  5. Improved Safety: Automation minimises the need for manual lifting and handling, reducing the risk of workplace injuries and RSI occurring.

Conclusion

By automating depalletising and cross stacking of pallets, businesses can achieve greater efficiency, reduce costs, and improve overall operational safety. These systems eliminate the need for labour-intensive manual handling and reduce the risk of RSI injuries occurring, ensuring a seamless transition between different pallet types. As technology continues to advance, these systems will no doubt become increasingly essential in maintaining competitive and efficient supply chain operations.

If you would like to know more about the Granta depalletising and repalletising systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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