Can Palletiser Systems Work with AGVs?

Posted on September 12, 2023 by Granta

Yes, palletiser systems can work in conjunction with Automated Guided Vehicles (AGVs) to automate and streamline material handling and palletising processes in warehouses and manufacturing facilities. This combination of technologies can enhance efficiency, reduce labour costs, and improve overall productivity. The two key ways in which AGVs are used to work alongside palletiser systems are shown below:

  1. Product Delivery: AGVs can be used to transport raw materials or finished products to and from the palletiser. They can pick up products from production lines, storage areas, or other locations and deliver them to the palletiser’s loading area.
  2. Pallet Transport: Once the palletiser has completed the stacking process, the AGV can transport the loaded pallets to designated storage areas or shipping docks. AGVs can navigate autonomously and follow predefined routes to ensure efficient transport.

There are many benefits to using AGVs in this way, and some of these benefits are outlined below:

  1. Integration and Coordination: The AGVs and palletiser system can be integrated into a centralized control system, allowing for seamless coordination and communication between these machines. This integration ensures that the right products are delivered to the palletiser at the right time and that the pallets are transported to their destination without delays.
  2. Flexibility: AGVs can be programmed to adapt to changes in production schedules, product types, and palletising patterns. This flexibility is valuable in environments where there is a need for frequent product changeovers or varying pallet configurations.
  3. Safety: Safety features such as sensors, cameras, and collision avoidance systems are incorporated into AGVs to ensure safe interaction with the palletiser and other equipment, as well as to protect workers in the vicinity.
  4. Efficiency and Labour Savings: The combination of AGVs and palletiser systems can significantly reduce the need for manual labour in material handling and palletising tasks, leading to cost savings and increased operational efficiency. They also reduce the need for multiple conveyors to transport product, thus creating further cost and space savings.

Overall, the integration of palletiser systems with AGVs is part of the broader trend toward automation and Industry 4.0 principles in manufacturing and logistics. This combination allows for smoother and more efficient operations, reduces the risk of errors, and enables businesses to adapt to changing demands more effectively.

If you would like to discuss your specific application in more detail, please contact us on 01223 499488 or helpline@granta-automation.co.uk.

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What is the Best Palletiser for use in the Food Industry?

Posted on September 12, 2023 by Granta

The “best” palletiser for use in the food industry can vary greatly depending on your specific needs, production volume, space constraints, and the type of food products you’re dealing with. There isn’t a one-size-fits-all answer. However, there are a several generic factors that are important to consider which are listed below.

  1. Type of Food Product: Different food products have varying shapes, sizes, and packaging requirements. Some palletisers are better suited for handling specific types of food, such as bottles, boxes, bags, or cans. There are multiple gripper types available to suit different applications and the type of gripper you will need will depend on the products attributes
  2. Throughput and Speed: Depending on your production volume, you’ll need a palletiser that can handle your required throughput. Collating technology and multi product gripping may be required for higher speed applications. This may involve picking and placing a row of product at a time, or picking and placing complete layers.
  3. Automation Level: Automated palletisers range from systems that require manual placing of empty pallets and removal of full pallets, through to fully automated cells that include automated pallet feeding and slipsheet placement, with full pallets being fed out of the cell, enabling the system to continuously run. The level of automation you choose will depend on your budget, available space, and labor resources.
  4. Footprint and Layout: Consider the available space in your facility and the layout of your production process. It is importance to consider infeeds and outfeeds to the palletiser, access requirements for existing machinery, and fork lift/pallet truck access for removing finished pallets of product from the system.
  5. Flexibility: The ability to handle various packaging configurations and adapt to different products can be important, especially if you produce a wide range of food items.
  6. Maintenance and Reliability: Look for a palletiser that is known for its reliability and ease of maintenance to minimize downtime. It is also important to choose a company that has a good support system available, including both on site and remote support options.
  7. Integration: Ensure that the palletiser can easily integrate with your existing production line equipment and software systems.
  8. Safety: Palletisers should adhere to safety regulations and have features that protect operators and prevent accidents.
  9. Future proof: Ensure that the system you choose is future proof and can be modified as your requirements change. A modular system is the best type of system for this.

Based on these factors, there are several types of palletisers commonly used in the food industry:

  • Robotic Palletisers: Robotic palletisers use industrial robots to pick, place, and stack products onto pallets. They are highly versatile and can handle various product types and sizes. Robotic palletisers are often used in industries with frequent product changes.
  • Layer Palletisers: Layer palletisers are designed to stack entire layers of products onto pallets at once. They are commonly used for products that are palletised in consistent layers, such as cases of beverages or boxes.
  • Bag Palletisers: These palletisers are specialised for handling bags of various sizes and shapes, such as sacks of flour, pet food, or fertilizer. They can use robotic arms or mechanical systems to stack bags onto pallets.
  • Case Palletisers: Case palletisers are designed to handle individual cases or boxes of products, often found in industries like food and beverage, pharmaceuticals, or consumer goods. They can be equipped with various end-of-arm tools, such as vacuum grippers or clamps. Row grippers and layer formers can also be used to enable the palletiser to lift multiples or complete layers of product at a time.
  • De-palletisers: While not exactly palletisers, de-palletisers are machines used to remove products or materials from pallets. They are often used in industries like recycling or food and beverage to unload products from incoming pallets.
  • High-Level Palletisers: These palletisers are typically used in industries with high production rates. They can stack products at high speeds and are often integrated into conveyor systems. High-level palletisers can be either robotic or conventional machines.
  • Low-Level Palletisers: Low-level palletisers are usually smaller and operate at lower speeds compared to high-level palletisers. They are commonly used in smaller production facilities or when cost considerations are a priority.
  • Mixed-Load Palletisers: These systems are designed to create mixed-load pallets with multiple product types or SKUs on the same pallet. They are commonly used in distribution centres and warehouses.

Remember that the best palletiser for your food industry needs depends on a careful assessment of your production line, the type of food products you’re working with, your budget, available space, and your desired level of automation. It’s recommended to reach out to manufacturers, discuss your requirements in detail, and potentially request demonstrations or references to find the most suitable palletiser for your specific situation.

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Problems with Robotic Palletisers

Posted on September 7, 2023 by Granta

Robotic palletisers are automated machines designed to stack and organise products onto pallets. While they offer many benefits, they may also come with potential problems and challenges. Here are some common problems associated with robotic palletisers, and the suggested solutions to overcome these problems.

  1. Programming Complexity
    Problem: Setting up and programming a robotic palletiser can be complex and time-consuming. It requires expertise in robotics and automation, and any mistakes in the programming can lead to operational issues.Solution: Invest in user-friendly programming interfaces and easy-programming software that simplifies the robot programming and enables your factory staff to reprogram the robot for new products and stack patterns.
  1. Product Variability
    Problem: Robotic palletisers may struggle with handling products of different shapes, sizes, and weights. They often require customization or additional tooling for various product types.Solution: Implement adaptive grippers and end-effectors that can handle a wide range of product sizes and shapes. Consider modular tooling that can be easily swapped for different products.
  1. Speed and Efficiency
    Problem: While robots are generally efficient, they may not always be as fast as needed for high-volume production lines. Speed limitations can lead to production bottlenecks.Solution: Optimize the layout of your production line to ensure a smooth flow of products to the robotic palletiser. Consider upgrading to faster robots if necessary.
  1. Maintenance
    Problem: Like any machinery, robotic palletisers require regular maintenance to ensure they operate smoothly. Unexpected breakdowns or downtime can be costly.Solution: Implement a proactive maintenance schedule with regular inspections and preventive maintenance tasks. Invest in high-quality components and robots with a reputation for reliability.
  1. Palletising Patterns
    Problem: Achieving optimal palletising patterns for different products can be challenging. Ensuring stability and proper weight distribution on pallets is crucial to prevent damage during transport.Solution: Utilise advanced software algorithms that can automatically generate optimised palletising patterns. Palletiser with easy-programming software will have this included in the software and your factory staff will be able to re-program stack patterns in just minutes.
  1. Product Handling
    Problem: Delicate or irregularly shaped products can be difficult to handle for robotic palletisers, potentially leading to product damage or misplacement.Solution: Invest in grippers and end-effectors with adjustable sensitivity and compliance to handle delicate products. Implement vision systems to improve product recognition and handling.
  1. Safety
    Problem: Robots in the workplace require strict safety measures to prevent accidents and injuries. This includes safety fencing, emergency stop systems, and ongoing safety training for personnel.Solution: Ensure compliance with safety regulations, including proper safety fencing, emergency stop systems, and safety training for personnel. Regularly review and update safety procedures.
  1. Integration
    Problem: Integrating a robotic palletiser into an existing production line can be complex, especially if the equipment and software are not compatible.Solution: Work closely with experienced system integrators to ensure seamless integration of the robotic palletiser into your production line. Choose equipment and software that are compatible with your existing systems.
  1. Cost
    Problem: The initial investment for a robotic palletiser can be significant, and the return on investment (ROI) may take some time to realize. Smaller businesses with limited budgets may find it challenging to justify the expense.Solution: Calculate the long-term ROI to justify the initial investment, it is well worth looking at the cost savings relating to intangible benefits as well then investigating this. Explore financing options or consider leasing equipment to spread out the cost. Look for grants or incentives that may be available for automation investments.
  1. Software and Control Issues
    Problem: Software glitches or control system malfunctions can lead to errors in palletising, causing delays and potentially damaging products.Solution: Keep software and control systems up to date with regular updates and maintenance. Invest in redundancy and fail-safe mechanisms to minimize the impact of software glitches.
  1. Maintenance Costs
    Problem: Maintaining and servicing robotic palletisers can be expensive, especially if specialized technicians are required.Solution: Negotiate service contracts with the equipment manufacturer or a trusted service provider to control maintenance costs. Train in-house staff to perform routine maintenance tasks. Typically, a good robot palletiser system with an industrial robot will last for many years with minimal maintenance costs
  1. Environmental Conditions
    Problem: Robots may be sensitive to environmental factors like dust, temperature fluctuations, or humidity, which can affect their performance.Solution: Create a controlled environment for the robotic palletiser if environmental factors are a concern. Use protective enclosures or clean rooms as needed.
  1. Operator Training
    Problem: Employees responsible for overseeing and maintaining the robotic palletiser must receive adequate training. Lack of trained personnel can lead to inefficiencies and downtime.Solution: Invest in comprehensive training programs for operators and maintenance personnel. Ensure that your team is well-prepared to operate and troubleshoot the robotic palletiser.
  1. Product Changeovers
    Problem: Switching between different product types can require reprogramming and adjustments, which can lead to downtime.Solution: Develop standardized changeover procedures and tools to minimize downtime during product transitions. Consider using quick-change tooling for flexibility.

Continuous monitoring, feedback, and improvement are essential to address these problems effectively. Regularly assess the performance of your robotic palletiser and make adjustments as needed to optimize its operation within your specific production environment.

As outlined above, whilst there are some problems that are associated with robotic palletisers, with good training, regular maintenance and a well-established integrator, these issues can be overcome or at least minimised.

If you would like to discuss your specific application in more detail, please contact us on 01223 499488 or helpline@granta-automation.co.uk.

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Can a Palletiser Palletise Product Off Multiple Production Lines?

Posted on August 1, 2023 by Granta

Yes, a palletiser can palletise products from two or more separate lines, commonly referred to as “dual-line palletising” or “multi-line palletising”. This is a standard feature in many industrial palletising systems and is used to increase efficiency, optimize palletising operations, and reduce the need for additional palletising equipment.

In dual-line or multi-line palletising, products from two or more independent production lines are conveyed to the palletiser through their respective conveyors, and the palletiser can handle the multiple lines simultaneously. Here’s how the process typically works:

  1. Separate Conveyors: Each production line has its own conveyor system that feeds products to the palletiser. These conveyors typically run parallel to each other and can be set up side by side.
  2. Product Identification: The palletiser’s control system can identify the source of each product based on its origin line. This ensures that products from Line 1 are palletised together separately from products from Line 2, etc.
  3. Palletising Pattern: The palletiser’s software is programmed with the palletising patterns for each product line. Each line may have its unique stacking arrangement or palletising sequence.
  4. Robotic Palletising: The robotic arm of the palletiser picks up products from the various lines and places them onto the pallets based on their respective palletising patterns. With dual-line palletising, depending on the specific system setup, the palletiser will typically alternate between picking products from Line 1 and Line 2, ensuring a balanced and efficient palletising process. The system can also be set up to give palletising priority to one lane or the other, or to palletise on demand.

Benefits of dual-line and multi-line palletising:

  • Increased Throughput: By handling products from two or more lines at the same time, the palletiser achieves a higher throughput, reducing overall palletising time.
  • Space Optimization: A dual-line or multi-line palletising system allows manufacturers to use the same palletiser for multiple lines, optimizing floor space and reducing the need for additional equipment.

It’s important to ensure that the dual-line/multi-line palletising system is properly designed, and to ensure that the gripper head on the robot is suitable for picking and placing the products from the lines. The palletiser’s control system and software must be set up correctly to handle the different lines without any collision or safety issues.

A key factor to consider when choosing a double lane palletising system is the speed; the speed of the system will be defined by the number of cycles the robot can do in a minute multiplied by the number of products it can lift per cycle. Some systems have row gripping which enables the system to pick and place multiples of product, for a better understanding of this see https://www.granta-automation.co.uk/news/how-many-boxes-or-bags-per-minute-or-hour-can-a-palletiser-palletise/.  It is very important to ensure that the speed requirements including any pallet moving and slipsheet placement between layers is met, as having a dual lane system does halve the maximum speed per lane of a single lane system.

If you are considering implementing a dual-line or multi-lane palletising system, it’s best to consult with palletiser manufacturers or automation experts. They can provide guidance on the most suitable setup for your specific production requirements and ensure smooth integration with your existing production lines.

If you would like to discuss your specific application in more detail, please contact us on 01223 499488 or helpline@granta-automation.co.uk.

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How Many Boxes or Bags Per Minute or Hour Can A Palletiser Palletise?

Posted on August 1, 2023 by Granta

The number of boxes or bags a palletiser can handle per minute or hour depends on several factors, including the specific model and type of palletiser, the size and weight of the boxes/bags, and the complexity of the stacking pattern. Palletisers are machines used to automatically stack boxes or bags onto pallets for efficient transportation and storage.

There are different types of palletisers, such as robotic palletisers and conventional palletisers, each with its own speed and capabilities. High-speed robotic palletisers tend to have a faster throughput compared to conventional palletisers.

There are also a wide variety of griper head types available on a robotic palletiser, and each of these is able to lift different amounts of product per cycle. Depending on the product and gripper size, robot grippers can pick many products at a time speeding up the throughput of the palletiser, so an accurate calculation of boxes/bags per minute/hour will need to be done for your application to get the specific cycle time for your application.

This table does however show some typical speeds that can be achieve using different gripper types.  They are only approximate average speeds and as each application is unique the accurate speeds would need to be calculated based on the application.

The speed that the robotic palletising system can run in products stacked per minute is calculated as follows:

cycles per min with the robot and gripper
X
no of products picked by the gripper each cycle
=
palletising speed in products per minute

To convert boxes/bags per minute (BPM) to boxes/bags per hour (BPH), you can use the following formula:

BPH = BPM * 60

So, for example, a palletiser running at 100 BPM can handle:

100 BPM * 60 minutes = 6,000 boxes/bags per hour

Keep in mind that these numbers are general estimates, and actual performance may vary depending on the specific palletiser and the application. Additionally, the manufacturer’s specifications will provide the most accurate information regarding the palletiser’s speed and capabilities.

There are also several other contributing factors to consider that can affect the speed in addition to the cycle time of the palletising system such inclucing;

  • Conveyor speeds
    Often the restriction in speeds can be the conveyor system feeding the palletiser. Advanced conveyor systems are required when you get over 25 products per minute in order to control the product flow into the palletiser. An advanced conveyor system will orientate the product correctly whilst keeping it sequenced, and will stop/start as required for feeding into the palletiser system. Whilst a palletiser might be able to run at significantly higher speeds it is essential to get the conveyor system feeding the palletiser correct to enable the optimum performance of the palletising system.
  • Pallet feeding
    Another restriction in speed is the feeding of finished pallets out of the system and the feeding of new pallets into the system. A high speed palletising system will need to have an auto pallet feed system, where the new pallets can be fed into the cell without the palletising system having to stop.  This is often done by installing a auto pallet feeder which can be loaded form outside the palletising cell, and will then feed the emptly pallets into the cell via a conveyor system.  Filled pallets will also need to be able to leave the palletising cell without the palletiser having to stop palletising.  They is typically done using pallet conveyors and light curtains, which enable the pallet to safely leave the palletising cell without the palletiser having to stop.
  • Slipsheet placement
    Another restriction on the cycle time of a palletising cell is the time needed for slipsheet placement. Each slip sheet that is placed creates a break in the palletising process, and reduces the cycle time per hour by the amount of slipsheet placement/time taken to place the slipsheet per hour. Slipsheet placement therefore needs to be taken into account in any cycle time calculations.

If you could like help with calculating cycles times for your process, please contact us on 01223 499488 or helpline@granta-automation.co.uk.

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What Are The Benefits of a Modular Palletiser System?

Posted on August 1, 2023 by Granta

A modular palletising system offers several benefits that make it a popular choice for various industries. Here are some of the key advantages:

  1. Flexibility: The modular design allows for easy customization and configuration to match specific production requirements, product types, and palletising patterns. Companies can choose the appropriate modules and arrange them in different ways to achieve the desired palletising solution.
  2. Scalability: Modular palletisers can be easily scaled up or down to accommodate changes in production demands. As business needs evolve, additional modules can be added to increase throughput or reconfigured to suit new production layouts.
  3. Cost-Effectiveness: The modularity of the system enables companies to invest in only the necessary components, avoiding unnecessary expenses on features that may not be needed. This cost-effectiveness is particularly beneficial for smaller operations or those with varying production volumes.
  4. Easy Integration: These systems are designed for seamless integration with existing production lines and processes. The plug-and-play nature of modular components simplifies installation, reducing downtime during setup.
  5. Versatility: Modular palletising systems can handle various product types, sizes, and weights. With the ability to swap out end-of-arm tooling and adjust settings, the system can accommodate different products without major reconfiguration.
  6. Maintenance Efficiency: Individual modules can be easily serviced or replaced when needed, streamlining maintenance efforts and minimizing downtime. This is especially advantageous in industries where uptime is critical.
  7. Future-Proofing: As technology advances and industry requirements change, modular palletisers can be upgraded or enhanced by adding newer modules or integrating advanced software and controls.
  8. Reduced Footprint: The flexibility of modular palletisers often allows for more efficient use of floor space, making them suitable for facilities with limited space.
  9. Enhanced Safety: Modular palletising systems come with built-in safety features, ensuring compliance with industry regulations and reducing the risk of accidents during operation.
  10. Quick Deployment: Due to the pre-designed and tested nature of modular components, these systems can be deployed more rapidly than fully customized palletising solutions.
  11. Improved Productivity: The adaptability and efficiency of modular palletisers contribute to enhanced productivity and optimized palletising processes, resulting in increased throughput and reduced manual labour requirements.

The benefits of a modular palletiser system make it an attractive choice for various industries, including food and beverage, consumer goods, pharmaceuticals, logistics, and more. By leveraging modularity, companies can design and implement palletising solutions that align precisely with their specific needs, thereby improving overall production efficiency and cost-effectiveness.

To find out more about modular palletising systems, or if you would like to discuss your application in more detail, please contact us on 01223 499488 or contact us at helpline@granta-automation.co.uk.

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What Is A Modular Palletising System?

Posted on July 28, 2023 by Granta

 

A modular palletising system is a type of palletising system that is designed with modularity in mind. It consists of individual modules or components that can be easily combined, rearranged, or customized to create a palletising solution tailored to specific production needs. These modular systems offer flexibility, scalability, and adaptability, making them suitable for a wide range of industries and applications.

The key features of a modular palletising system include:

  1. Individual Modules: A modular palletising system is composed of distinct modules, such as conveyors, robots, pallet wrappers, pallet dispensers, and slipsheets. Each module serves a specific function and can be interchanged or upgraded as needed.
  2. Customizable Configurations: The modular design allows for various configurations, enabling the palletising system to be adapted to fit different production layouts, space constraints, and product types.
  3. Easy Integration: These systems are designed for straightforward integration with existing production lines or manufacturing processes. The modular components can be seamlessly integrated into the workflow without major disruptions.
  4. Scalability: As production needs change or expand, modular palletising systems can be easily scaled up or down by adding or removing modules as required.
  5. Simplified Maintenance: The modularity of the system simplifies maintenance and troubleshooting, as individual modules can be serviced or replaced independently.
  6. Quick Installation: Modular palletising systems often have faster installation times compared to fully customized systems since the components are pre-designed and tested off site prior to intall.
  7. Cost-Effective: By only selecting and installing the necessary modules, companies can avoid investing in unnecessary features, making these systems more cost-effective.

Modular palletising systems are available in various configurations, and the choice of configuration depends on the specific requirements of the application, such as production rate, product types, and pallet patterns.

These systems are commonly used in industries such as food and beverage, consumer goods, pharmaceuticals, and logistics, where versatility and adaptability are crucial to meet changing market demands.

The advantage of a modular palletising system lies in its ability to offer a tailored solution while providing the flexibility to adjust and expand the system in the future. Companies can work with palletiser manufacturers or automation experts to ensure that they design and configuration of the modular palletising system meets their unique production needs and optimizes palletising efficiency.

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What is a Vacuum Gripper?

Posted on July 21, 2023 by Granta

 

Vacuum grippers are a type of end effector that uses suction to lift and manipulate objects. They are widely used for robotic palletising, which is the process of stacking and arranging products on pallets for transportation or storage. Vacuum grippers have many advantages over other types of grippers, such as:

  • They can handle a variety of objects, such as boxes, display boxes, cartons and some types of packed products and bags.
  • They can lift objects from above, without needing to grip them from the sides or below.
  • They can distribute the payload evenly across the object’s surface, avoiding deformation or damage.
  • They can be customized to fit different sizes and shapes of objects, by adjusting the number and position of suction cups or valves.
  • They can save energy and reduce noise, by using self-closing valves that only activate when needed.

A vacuum gripper works by using suction to lift and place objects onto a pallet. It consists of a electrical vacuum pump or a venturi vacuum pump connected to a vacuum head with suction cups or a foam pad. The vacuum gripper’s design and construction can vary depending on the application requirements. Some grippers have multiple suction cups arranged in an array for increased gripping capacity and flexibility, whereas other vacuum grippers have a foam pad. The vacuum pump creates a negative pressure inside the hose and the head, which causes the suction cups or foam pad to stick to the surface of the object. The robot arm then moves the object to the desired location on the pallet and releases the suction by turning off the pump or opening a valve.

Vacuum grippers are particularly useful in situations where traditional mechanical grippers may not be suitable, such as when handling delicate or irregularly shaped objects. They are commonly used in industries such as manufacturing, warehousing, and logistics.

Some examples of the different types of vacuum gripper are shown below.

Vacuum Layer Gripper

Row Vacuum Cup Gripper

Row Vacuum Gripper

Vacuum Bag Gripper

Vacuum Box Gripper

 

It’s worth noting that while vacuum grippers are efficient for many applications, they do have limitations. They rely on a certain amount of airtight seal, so they may not work effectively on some very porous or rough surfaces. Additionally, objects with irregular or curved surfaces may require specialized gripper designs or multiple suction cups to ensure a reliable grip.

Vacuum grippers are one of the best options for robotic palletising, as they offer versatility, speed, and reliability. They can improve the productivity and quality of the palletising process, while reducing the workload and risk of injury for human workers.

If you would like to discuss your application in more detail, please contact us on 01223 499488 or contact us at helpline@granta-automation.co.uk.

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What Weight Can a Robotic Palletiser Lift?

Posted on July 21, 2023 by Granta

The weight of product that a robotic palletiser can lift depends on the specific model and capabilities of the system. Robotic palletising systems are designed to handle a wide range of product weights, but there are limitations based on their payload capacity and mechanical capabilities.

Standard industrial robotic palletisers typically have a payload capacity of around 90-120kg, with heavy-duty robots having an even higher payload capacity of more than 1000kg. The weight of the gripper head also needs to be taken into account when calculating the payload capacity of the robot and the weight it can lift. Cobot palletisers have a lot lower payload of approximately 8-20KG, but realistically after the weight of the gripper is taken off, the payload is often 2kg less than this.

When selecting a robotic palletiser, it’s essential to consider the weight of the boxes you intend to palletise and ensure that the chosen robot can handle the maximum weight without exceeding its payload limits. Additionally, the size, shape, and stability of the boxes may also play a role in determining the palletiser’s performance and the overall stacking efficiency.

It is important to consult with the manufacturer or supplier of the robotic palletiser to get specific details about the model’s payload capacity and suitability for your application. They can provide guidance on the appropriate robot for your specific needs and help ensure smooth and efficient palletising operations.

If you would like to discuss your application in more detail, please contact us on 01223 499488 or helpline@granta-automation.co.uk.

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Bag Palletiser

Bag Palletiser

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Barrel Palletiser

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Crate Palletiser

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Problems With Industrial Robot Palletisers

Posted on July 18, 2023 by Granta

Industrial robot palletisers, like any complex machinery, can face several problems that can affect their performance and efficiency. Some of the common issues associated with industrial robotic palletisers, and their potential solutions include:

1. Programming errors

Problem: Incorrect or incomplete programming can lead to robotic palletisers not functioning as intended. This can result in errors in picking, placing, or stacking products, leading to misaligned or unstable pallets.

Solution: Ensure that the robotic palletiser is programmed correctly and that the software is up to date. This may involve working with experienced programmers or collaborating with the manufacturer to optimize the programming for your specific application. There are also systems available that have a tried and tested ‘easy programming’ software which helps to eliminate errors. Also, ensuring that the palletiser system has been commissioned and tested at the integrators site before being installed on your site will minimise the risk of programming errors occurring.

2. Mechanical failures

Problem: Robotic palletisers rely on various mechanical components, such as motors, gears, belts, and grippers, to perform their tasks. These components can experience wear and tear over time, leading to malfunctions, breakdowns, or reduced accuracy. Failure to perform routine maintenance tasks, such as lubrication, inspection, and cleaning, can result in increased wear and tear, decreased accuracy, and eventually, breakdowns.

Solution: Regular maintenance is crucial for the smooth operation of robotic palletisers. Implement a proactive maintenance schedule to keep the robotic palletiser in optimal working condition. This includes routine inspections, safety checks, lubrication, cleaning, and replacing worn-out components. Adherence to the manufacturer’s recommended maintenance guidelines is essential.

3. Sensor malfunctions

Problem: Robot palletisers often use sensors to detect and locate products, pallets, or obstacles in their workspace. If these sensors become faulty or misaligned, it can result in errors during the picking and placing process, leading to misplaced or dropped items.

Solution: Regularly clean and inspect the sensors to ensure their accuracy. Ensure that sensors have not got knocked or moved, and if any sensors are malfunctioning or misaligned, they should be promptly repaired or replaced.

4. Pallet or product variations

Problem: Industrial environments often involve handling a wide range of products with different shapes, sizes, and weights. If the robot palletiser is not designed or programmed to accommodate these variations, it may struggle to properly grip, lift, or stack certain products, causing errors or product damage.

Solution: If the robot palletiser struggles with handling certain products, consider adjusting or replacing the gripper to accommodate different sizes, shapes, or weights. Gripper customisation can improve the palletising process and reduce errors. If you are considering a new palletiser ensure you scope for the full range of products and ask for a demo with your products on a system before purchasing.

5. Integration challenges

Problem: Integrating a robot palletiser into an existing production line can present technical challenges. Incompatibilities with existing equipment, software, or control systems can lead to difficulties in achieving seamless integration and may require additional modifications or adjustments.

Solution: Ensure proper connectivity, compatibility, and integration to prevent communication issues. Plan any software link up required in advance of installation. Collaborate with suppliers and technicians and establish a good working relationship with the manufacturer or supplier of the robotic palletiser. They can provide valuable support, guidance, and troubleshooting assistance. Their expertise can help diagnose and resolve specific issues quickly and effectively.

To safeguard your robotic palletising system against these issues, it is important to ensure the system has been properly programmed, perform regular maintenance, and provide necessary training to operators. Additionally, involving experienced technicians and collaborating with the manufacturer or supplier of the palletiser can help diagnose and resolve specific issues efficiently. By doing this, you can enhance the performance, reliability, and efficiency of industrial robot palletisers, leading to smoother operations and improved productivity in your facility.

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Bag Palletiser

Bag Palletiser

Barrel Palletiser

Barrel Palletiser

Box Palletiser

Box Palletiser

Crate Palletiser

Crate Palletiser

Tray Palletiser

Tray Palletiser

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