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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Can You Automatically De Stack from a Pallet onto a Machine

Posted on June 30, 2023 by Granta

Yes, it is possible to automate the process of stacking items from a pallet onto a machine; this process is often known as depalletising or pallet de-stacking. It is effectively the reverse operation of palletising product, and automating this process can significantly improve efficiency, speed, and accuracy in industrial processes.

Depalletising is typically performed where the items need to be unloaded from the pallet and further processed, distributed, or placed into another system or production line. There are various methods and technologies that can be used to achieve automated de-stacking. Here are a few examples:

  1. Robotic depalletising: Robotic depalletising involves the use of a robotic arm or gantry systems to unload items from the pallet. These robots can be programmed to a pre-set stack pattern or can be programmed to identify and locate the items on the pallet using sensors, cameras, or other detection mechanisms. It will then grip and lift them, and place them onto a conveyor or other downstream equipment. Typically, a vacuum pick gripper is used for robotic depalletising and will either pick product singularly or in multiples depending on the product and speeds required. Robotic depalletising offers high speed, precision, and efficiency, making it suitable for high-volume operations or repetitive tasks.

  2. Layer depalletising: Layer depalletising involves removing entire layers of items from the pallet simultaneously. It often employs mechanical or robotic systems that can lift and transfer an entire layer of items onto a conveyor or other equipment. Layer depalletising is efficient and can be suitable for operations where items are uniformly stacked on the pallet. Once the product is placed on the conveyor, devices such as pushers, diverter arms, or pneumatic actuators that push or separate the items from each other, are be used to separate the product as required.

  3. Push-off depalletising: Push-off depalletising utilizes mechanical devices to push or slide items off the pallet. This method is commonly used for items that have a low coefficient of friction, such as cases or boxes. The mechanical device pushes the items in a controlled manner, allowing them to slide off the pallet and onto a conveyor or other equipment. Once the product is placed on the conveyor, devices such as pushers, diverter arms, or pneumatic actuators that push or separate the items from each other, are be used to separate the product as required.

These are just a few examples of automated systems that can be used for de-stacking items from a pallet into a machine. The specific choice of automation method depends on factors such as the type of items being depalletised, the desired speed and precision required, and the available budget. Implementing automated de-stacking systems often requires careful planning, integration, and customization based on the specific requirements of the operation to ensure that you get the best outcome for your requirements.

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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Can A Palletiser Stack on Different Sized Pallets?

Posted on June 28, 2023 by Granta

Yes, a palletiser can stack products on different sized pallets. Palletisers are designed to handle various pallet sizes and configurations to accommodate different packaging requirements and industry standards. The specific capabilities of a palletiser depend on its design and features.

In the UK, the most commonly used pallet is the standard wooden pallet known as the ‘UK Standard Pallet’ or ‘Chep pallet’. The dimensions of the UK standard pallet are 1200 mm x 1000 mm (47.24 inches x 39.37 inches). The Euro pallet is also prevalent in the UK, especially in European trade. This has dimensions of 1200 mm x 800 mm (47.24 inches x 31.50 inches). 

Most palletisers are equipped with auto adjusting mechanisms that allow them to adapt to different pallet sizes. These adjustments ensure that the palletiser can properly stack and arrange the products on the pallet, regardless of its size. Some of the key factors that need to be considered to enable the palletiser to stack onto different sizes of pallet are:

  • Software: Palletisers are typically equipped with an HMI, which allows for programming and customisation. The operator can input the dimensions of the pallet being used into the HMI system. The software then adjusts the movements and stacking patterns of the palletiser accordingly to ensure proper alignment and stacking on the specific pallet size. On some palletiser systems, the pallets sizes are already saved and stored in the program; enabling you to simply select the correct pallet size and the palletiser software will then auto generate the most efficient stack pattern.
  • Where the palletiser is stacking on to pallet stack positions on the floor, the positioning of these pallet stack positions needs to be carefully considered.  This is due to the fact that for each of the different pallet sizes that the palletiser is going to be stacking, there needs to be enough space for each pallet type to be placed, and there also needs to be space around the stack position to allow for any overhang of the robot gripper as it stacks the pallet.
  • If the pallets are fed into the palletising system by auto feed conveyors, the width of the conveyor will define the largest pallet size that can be used. It is important to ensure that the conveyor system will work for the largest pallet size you wish to palletise onto.
  • Automated pallet feeder systems typically only take one size of pallet. Some automated pallet feeders are adjustable, but you would normally need a separate pallet feeder for each size of pallet.
  • If the system is a robotic palletiser, then the reach of the robot needs to be considered. Some smaller robots and cobot palletiser systems may not have enough reach on the robot for UK standard or Chep pallets.  This is something that especially needs to be considered if the palletiser is manufactured in Europe as it is likely to have been designed for palletising onto Euro pallets that are smaller in size than the UK standard pallets.
  • Another factor that needs to be considered when purchasing a palletiser to stack onto different sizes of pallets is how does the product sit on the pallet.  For example; do the boxes/bags/product overhang the side of the pallet? What height is the finished pallet stack?  All of these factors affect the reach of the palletiser and positioning of the pallet that the product is going to be palletised on to.
  • There are many different types of pallet construction. The pallet construction type and quality of construction is very important in an automated palletising system. For example; if the pallet has full perimeter boards around the base, a standard conveyor system will work for transferring the pallet through the palletising system.  However, if the pallet just has legs, then a different type of conveyor system may be needed to the traditional roller conveyors that are typically used in a palletising system as the legs of the pallet would just jam between rollers.

It’s worth noting that some palletisers may have limitations on the range of pallet sizes they can handle. For example, a particular palletiser may have a minimum and maximum pallet dimension specified by the manufacturer. It’s essential to consult the equipment specifications or contact the manufacturer to ensure that a palletiser can accommodate the specific pallet sizes you intend to use.

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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Advantages and Disadvantages of Automated Palletisers

Posted on June 23, 2023 by Granta

Automated palletisers offer several advantages and disadvantages. However, each automated palletising application is unique, so there may be other advantages or disadvantages applicable to your situation that are not listed here.  Below are some of the key advantages and disadvantages of automated palletisers:

Disadvantages of Automated Palletisers:

Some of the key disadvantages of automated palletisers are listed below, however depending on the type of system you purchase and the company you purchase from, these disadvantages may not all apply.

  1. High Initial Investment: Implementing an automated palletizing system typically requires a significant upfront investment. The cost includes purchasing the equipment, installation, and integration with existing infrastructure. For small businesses or those with limited budgets, this initial investment may be a deterrent.  However, automated palletising systems are also available on leasing schemes which eliminates the requirement for any initial capital outlay.
  • Maintenance and Technical Support: Automated palletisers require regular maintenance to ensure optimal performance. They have complex mechanical and electrical components that may require specialized knowledge or technical support for repairs. Businesses need to budget for ongoing maintenance costs and have access to trained personnel or reliable service providers. Typically, an automated palletising solution will come with a support contract in place to ensure that the system is regularly checked and maintained.
  • Limited Flexibility for Irregular Products: While automated palletisers offer flexibility for a wide range of products, they may have limitations when it comes to irregularly shaped or fragile items. Certain products may not fit within the standard parameters of the palletiser, requiring manual intervention or alternative palletising methods.
  • Initial Setup and Programming: Setting up an automated palletising system and programming it to accommodate specific products and stacking patterns can be time-consuming. It may require technical expertise and thorough testing to ensure the system operates efficiently. Changes in product specifications or stacking requirements may also require reprogramming, which can lead to downtime and temporary disruptions. However, there are palletising systems on the market that have easy programming software as standard, enabling your factory staff to reprogram the robot for different product sizes quickly and easily.

Advantages of Automated Palletisers:

Automated palletisers have many different advantages, and the benefits for your company will be determined by your palletising requirements and how these will be met.  However, some of the more common advantages are listed below.

  1. Increased Efficiency: Automated palletisers can significantly improve the efficiency of palletising operations by handling high volumes of products at a faster rate compared to manual labour. They can work continuously without the need for breaks, resulting in increased productivity.
  • Consistency and Accuracy: Automated palletisers ensure consistent and accurate pallet stacking, minimising errors and reducing the risk of damaged products during transportation. They can precisely position each item according to the predefined stacking pattern, optimizing space utilization.
  • Reduced Labor Costs: By automating the palletising process, businesses can reduce their reliance on manual labour. This can lead to significant cost savings in the long run, as automated systems require less manpower, no breaks, and eliminate the need for manual lifting, which therefore reduces the risk of workplace injuries occurring.
  • Flexibility and Adaptability: Many automated palletisers are designed to handle a wide range of product types, sizes, and weights. They can be easily programmed by factory staff for different product sizes, and auto generate optimised stacking patterns to choose from; making them suitable for diverse industries and applications. This flexibility allows businesses to adapt to changing production requirements and market demands more effectively.
  • Integration with Production Lines: Automated palletisers can be seamlessly integrated with other production line equipment, such as conveyor systems, sorting machines, and packaging equipment. This integration enables a smooth flow of products from manufacturing to palletising to shipping, eliminating bottlenecks and optimising the overall production process.

Whilst these are some of the more common advantages and disadvantages of automated palletisers, it is important for businesses to evaluate their specific needs, production volumes, and budget constraints before deciding whether to invest in an automated palletising system.

You may find the following tools useful when analysing the advantages and disadvantages of automated palletising for your specific application:

You may also wish to complete a budget quote request on our project builder to get an understanding of what an automated palletising solution will cost for your specific application.  Simply fill in the details and we’ll get back to you with budget pricing within 24 hours. https://www.granta-automation.co.uk/project-builder

If you would like to discuss your specific application in more detail then feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.

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Advantages and Disadvantages of Cobot Palletisers

Posted on June 16, 2023 by Granta

Cobot palletisers, also known as collaborative robot palletisers, are robotic systems designed to work alongside human operators in palletising tasks. They offer several advantages and disadvantages, which are outlined below:

Advantages of Cobot Palletisers:

  • Increased productivity: Cobot palletisers can work continuously without experiencing fatigue or requiring breaks, resulting in higher production rates compared to manual palletising.
  • Enhanced safety: Cobots are designed to collaborate with humans in a shared workspace, equipped with advanced safety features such as force and proximity sensors. They can detect the presence of humans and adjust their speed or stop to avoid collisions, making them safer to work around than traditional industrial robots.
  • Flexibility and adaptability: Cobots are programmable and can be easily reprogrammed or reconfigured to handle different products or palletising patterns. This flexibility allows businesses to adapt to changing production needs and reduces the time and cost associated with retooling for new product lines.
  • Improved ergonomics: Cobot palletisers can perform repetitive and physically demanding tasks, reducing the risk of musculoskeletal/repetitive strain injuries for human operators. By automating the palletising process, cobots can free up workers to focus on more complex and value-added tasks.
  • Space efficiency: Cobots are often compact and can be installed in smaller spaces compared to traditional industrial robots. They can be integrated into existing production lines without significant modifications, saving valuable floor space in manufacturing facilities.

Disadvantages of Cobot Palletisers:

  • Cobot palletisers normally have to run too slow to be commercially viable if you run them in collaborative mode for palletising. As a result, nearly all cobot palletiser installations still need some element of guarding or area safety scanners to enable the cobot to be run faster and still be safe and compliant with CE and UKCA requirements.
  • High initial investment: Implementing cobot palletisers can involve a significant upfront investment, including the cost of the robot, necessary safety measures, and programming or integration with existing systems. This initial cost may pose a barrier to adoption for some businesses, particularly small and medium-sized enterprises (SMEs).
  • Limited payload and speed: Cobots typically have lower payload capacities and slower operating speeds compared to larger industrial robots. While they can handle many palletising tasks, certain heavy or high-speed applications may still require traditional industrial robots.
  • Complex programming: Programming cobots can require specialized knowledge and expertise, making it challenging for non-technical personnel. Although efforts have been made to simplify programming interfaces, it may still require additional training or hiring of skilled personnel to operate and maintain the cobot palletisers.
  • Integration challenges: Integrating cobot palletisers into existing production lines can be complex, especially if the infrastructure or control systems are not compatible. The coordination between cobots and other machinery, conveyor belts, or sensors may require additional engineering and customization.
  • Dependence on humans: While cobots are designed to collaborate with humans, they still rely on human operators for tasks such as supplying materials or troubleshooting issues. This human dependency may introduce inefficiencies if the cobots have to wait for human intervention or if human operators are not available when needed.

Please note that many low cost cobots palletisers solutions are sold with a certificate of incorporation for CE / UKCA which means they are not fully safety compliant until they have been set up with the relevant safety, integration and guarding, and then properly certified with a CE/UKCA certificate of conformity, before use. This is very important to understand as there are many non-compliant installations across the UK currently, where end users have not understood the significance of the certificate of incorporation rather than the normal certificate of conformity for a fully CE/UKCA marked ready to use machine.

It’s also important to note that the advantages and disadvantages of cobot palletisers can vary depending on the specific application, industry, and business requirements. Evaluating these factors is crucial in determining whether cobot palletisers are a suitable investment for a particular manufacturing operation.

If you would like more information on cobot palletiser systems, then please do get in touch on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.

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Fully Automatic Measuring and Programming Palletiser

Posted on June 6, 2023 by Granta

Auto programming is an advance on Granta’s already patented software options. By combining a laser measuring system and the Granta software, no programming is required at all to set up pallet stack patterns and program the robot.

The product is automatically measured as it enters the cell and if it is a different size to the previous product it will flag up a message offering to create a new stack pattern from the new product size.

The system is much more reliable than hand measuring product and entering dimensions and requires minimal human input. The use of more accurate dimensions also results in more accurate and neat stack patterns.

This fully automated programming is at the cutting edge of AI for the palletiser industry and opens up the opportunity to use robotic palletisers for very short runs of product, even as little as one pallet load.  It makes automated palletising viable where previously the set up time was prohibitive to automatically palletising.

If you would like more information on the Granta auto measuring and programming palletiser system, then please do get in touch on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.

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Manufacturing Root Cause Analysis Tools

Posted on May 19, 2023 by Granta

As we all know, the first step towards stopping an issue from reoccurring is to find the root cause of the problem and then fix this.  All too often we tend to fix the surface issues without taking the time to find the root cause. This is largely due to the fact that the root cause of the issue can often be masked by the surface issues: you may have a lot of customers complaining about late deliveries and assume it’s because despatch aren’t sending goods out in a timely manner, whereas the route cause may actually be the fact that manufacturing keep having breakdowns on a particular machine and aren’t getting goods to despatch at the appropriate time.  Using these tools to analyse the root cause will enable you to find the root cause issue in manufacturing rather than just fixing the apparent despatch issue.

There are six basic steps required in any root cause analysis to ensure that the issue is clearly identified and rectified.  These are:

  1. Recognise the problem – recognise when something isn’t what it should be.  Without recognition that there is an issue, it will never get resolved.
  2. Define the problem – it is important to define the problem so that everyone has a clear understanding of what the problem is and what the situation is that needs to be resolved.
  3. Analyse the problem – carry out analysis of the problems, find out the areas in which the issue occurs, how often the issue is occurring, and what the consequences are of this issue occurring.
  4. Find the root cause – having completed the above, it is then important to analyse and categorise the information you have gathered to enable you to identify what the most likely root cause of the issues is.
  5. Eliminate the root cause – having identified the root cause it is then important to eliminate this cause.  However, in some cases this may not be possible to eliminate entirely, but you should at least be able to improve the root cause issue in some way.
  6. Monitor the symptoms – this step is very important as it is essential to know if you have indeed eliminated the root cause issue.  This will also help you to identify if the root cause has now moved to a different area, having fixed the first root cause issue.

We’ve pulled together some of the best methods to help you with identifying the root cause of manufacturing issues. These are all well-established tools that have been used for many years in root cause analysis.

The Five Why’s
The 5 Why’s is one of the most effective methods of getting to the root cause of a problem.  Asking the question ‘Why?’ five times enables you to go deeper in your analysis of the problem and gain a clearer picture of where the underlying issues is.  An example of the 5 Why’s questioning method may go something like this

  1. Customer phoned and complained that his parcel was late – Why?
  2. The goods were despatched after the promised ship date – Why?
  3. Despatch received the goods a day later than they should have done – Why?
  4. Quality control didn’t release the goods when they should have done – Why?
  5. There had been a machine breakdown and repair and all of the goods in first few batches following this repair had to be inspected which made extra work for quality control and therefore the goods were late getting to despatch.

Having been able to identify the root cause, you are then in a position to start fixing the root cause and putting measure in place to ensure that if such an issue does occur again, there’s processes that can be followed to minimise disruption.  In this instance, it may be a case of putting a system in place to ensure there are more staff in quality control following a machine breakdown to ensure that there is enough resource to inspect the additional quantity of goods, and therefore goods don’t become late to despatch.

Fishbone Diagram

A fishbone diagram is typically used where there is no known root cause, and a very broad and in-depth brainstorm session has to take place to try and identify the root cause and enable a resolution to be reached.

The fishbone looks at the problem, and then helps you to break it down into subcategories that link back to the main issues, enabling you to investigate these subcategories in more details.

The fishbone diagram example below shows how it may be used to identify the roof case of an incorrect or delayed delivery.

There are many free downloadable templates that can be used for this analysis, however the headings show above are the ones most commonly used when trying to identify a manufacturing root cause issue as they are the key components of any manufacturing process.

Matrix Diagram
A matrix diagram is useful when you find there are a number of causes that have contributed to the problem, and you are trying to identify which of them is having the greatest impact. 

A matrix diagram looks like the below, and you will need to brainstorm the characteristics and possible cause of the problem to enable you to complete the matrix.  Once you have identified these, the characteristics of the problem can be plotted down the left-hand side of the matrix, and the possible cause of the issues should be plotted along the top.  The next step is then to start filling in the matric with a number defining how big an impact each of the causes has on the characteristics; ie. how big an impact does inaccurate planning have on production starting late?  Low impact is usually defined as a 1, and high impact would be 9.  Any number between 1 and 9 can be used. 

Having completed this table, scores for each possible cause should be added together and totalled at the bottom of the matrix. The possible cause with the highest score is typically the root cause that needs to be fixed.  Once you have fixed the initial root cause issue, you may find it useful to re-run this matrix as you may still be having the same type of issue, but the root cause may have moved on to another area.

Failure Mode and Effect Analysis (FMEA)

The failure mode and effect analysis tool is typically used to identify potential process, production and product issues before they actually occur.  It is usually used prior to the implementation of a new process, product or production process.  It identifies areas where the system is likely to fail, and then each potential failure is assessed for the severity of the failure, the occurrence of the failure, and detection of the failure.  Having identified these areas of risk and given them a risk score, these scores are then totalled to give a risk priority number (RPN).  Risks are then prioritised according to this score and action taken to reduce or eliminate the risk.

These are just four of the most commonly used root cause analysis tools, but as you can see, they will enable you go quickly get to the root cause of any manufacturing issues.  Just like when you identify bottlenecks in your production process, it is very important to continue to undertake root cause analysis once you have solved the first issue you identify.  This is because you will often find that when you fix one root cause, the issue often then moves to another place in the process.  Systematically working through and fixing these issues will enable you to have a far more effective and productive manufacturing process, which will typically result in a vastly improved OEE.

If you would like any more information on these analysis tools, then please do get in contact on 01223 499488 or helpline@granta-automation.co.uk. 

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Palletiser

Posted on May 15, 2023 by Granta

A palletiser is a system that stacks products onto pallets. There are many different types of palletiser on the market but the most common and versatile for different types of application is a robotic palletiser.

How do they work?

All palletisers are equipped with a gripper for picking product and an actuator or robotic arm for moving the gripper and product. An infeed conveyor feeds product into the palletiser and then products are picked by palletiser from the infeed conveyor and stacked onto pallets automatically. The pallets can be automatically fed into the system with a pallet feeder or they can be manually fed into the system with a forklift or pallet truck. Finished stacked pallets can be manually removed from the system, or automatically fed out of the system on conveyors. Automated pallet wrappers can also be included if required.

Example grippers

Example grippers used on a palletiser include:

  • Foam pad gripper – a foam pad gripper lifts product using vacuum
  • Bag gripper – a bag gripper has tines that close around the product.
  • Underneath gripper – an underneath gripper had a plate or tine that the product is slid onto and then clamped
  • Parallel Gripper – a parallel uses two plate to grip either side of the product.

More information on griper types and their suitability for different products is available here.

Application examples

There are many different applications in which a palletiser is used. Some of the more common applications are listed here:

Software

All palletiser systems will have some form of software controlling them, there is a wide range of software available from hard coded robot paths and stack patterns where every move is individually programmed by a skilled robot programmer, through to fully automatic software that any person that is familiar with computers can easily use to automatically generate stack patterns in less than 5 minutes. One of the fastest and most flexible software options on the market is the GA15 Palletising software.

Hardware

There is a wide variety of hardware needed in palletising cells such as conveyors, robots, actuators, grippers, control gear and much more. Some of the better palletiser systems on the market have modular systems that enable easy re-deployment and re-configuration of the system layout, along with very fast install. The GA15 Palletiser has a patented modular system that enables very fast install, modification, and accommodates almost any layout requirements, it is known as the Lego of palletisers.

Some key factors to consider when installing a palletiser include:

  • Palletiser speeds required
  • Product type and structural rigidity
  • Size and weight of products
  • Stack patterns
  • Integration requirements with upstream equipment
  • Types of pallets
  • Layout and available space requirements
  • Scanning and barcode reading for sorting products
  • Pallet wrapping requirements

More information on factors that need to be considered when installing a palletiser is available here.

Planning a palletiser install?

There are a lot of factors to consider to ensure you achieve successful palletiser installation, see below for a link to a guide to palletiser installations and downloadable template URS.  https://www.granta-automation.co.uk/news/palletiser-buying-guide/

Support

Having good support is a key to a successful palletiser install, both for ongoing training of new users and quick fault recovery. A good support contract will include 3 site maintenance visits per year and remote support availability.

Further information on palletisers

For further information on palletisers see https://www.granta-automation.co.uk/types-of-automation/robotic-palletising . You may also wish to download our free robotic automation resource pack https://www.granta-automation.co.uk/resources

If you would like to discuss this in more detail, or would like further information on the Granta GA15 Palletising system, then please do get in touch 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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Tray Palletiser

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Palletiser Buying Guide

Posted on May 8, 2023 by Granta

There are many different automated palletising systems available on the market, so we have put together a few key points that you should consider before investing. This will ensure that your investment will meet your current needs as well as being flexible enough to cope with any future changes in your requirements.

Key Benefits of An Automated Palletising System

1. Production Increase

Most companies typically experience a 40%+ production increase following the installation of an automated palletising system.  There are several reasons for this level of increase:

  • An automated system does not take holidays or breaks, so you production process does not need to stop
  • As the system is automated it forces a takt time. This means that the production process up the line has to keep to this takt time to ensure the palletiser is running at optimum speeds.
  • The system will run 24/7, working longer hours than an employee palletising by hand.
  • An automated system will achieve faster palletising speeds as there is no risk of the system stopping palletising due to distractions or RSI issues.

2. Fast Payback

The payback time on an automated system will be specific to your applications but it is usually very quick. Typically, as a rule of thumb, if you have the equivalent of one person employed full time for palletising, there is payback in less than 2 years.

3. Reduction in Health & Safety Claims

An automated palletising system completely removes the risk of repetitive strain injuries occurring, and therefore removes all of the associated costs that go along with RSI Health & Safety claims.

4. Other benefits

There are many other benefits associated with an automated palletising system, but some of the more commonly recognised benefits include; impressed customers, reduction in pallet stacking errors, improve stack quality, less transit damage, improved staff morale.

Return On Investment

The payback time for an automated palletising system is usually very quick, as not only do you remove the manual labour element and associated costs, but production can also continue to run throughout break times, etc.  This enables you to improve your production speed and throughput capacity, enabling you to product more product in less time.

To help you calculate the ROI for your project, we have created a free, downloadable robotics and automation resource pack www.granta-automation.co.uk/freepack. This pack includes an automation project payback calculator to help you determine your predicted return on investment based on production rates, shift times, HR costs, downtime, etc. It also includes an intangible benefits calculator as these are also something that need to be considered when working out your predicted return on investment as they can have a significant effect on the payback time of your project.

Things To Consider When Buying A Palletiser

1. Staff Training and Ease of Use

How easy is the palletising system to use? Can it quickly be reprogrammed to palletise different bag or box sizes? Can your staff reprogram it themselves? With some conventional palletising systems it can be very difficult to change the stacking pattern or bag placing positions without support from a specialist programmer. Therefore, it is important to ensure that the system you choose has easy programming software as this will enable your staff to reprogram the palletiser quickly and easily. This saves you the cost of having to call out an expensive robot programmer to reprogram the system when you need to change a stack pattern or bag size. It is also important to choose a system that has automatic stack generation software so that you can simply choose which stacking pattern you wish to use without having to spend time planning. Having a system with easy programming software will also ensure that your palletising system is future proof against any changes of product size or pallet type.

It is also important to ensure that your staff will receive training as part of the palletiser installation process.  A good training process will give your staff the needed skills to operate the palletising system in the most efficient and effective way.

2. Futureproof Throughput Capacity

What throughput do you need to achieve currently? What throughput are you looking to achieve in the future? Not only do you need to be sure that the system can meet your current throughput requirements, but it is also important to ensure that it has the necessary capacity to enable you to expand your sales and increase your throughput in the future. The last thing you want is to increase your sales only to find your palletiser has become a bottleneck in your production process! Spend time to think about where your business is heading in the future and ensure you invest in a system that will meet your future demands, or is easily scalable to meet them.

3. Stack Neatness

Neatly stacked pallets are key to your product reaching its final destination in the best condition. They also make for safer storage, and easier container and lorry loading. With several different methods of automated pallet stacking available, it is important that you choose a method that creates the best stack for your product. There are many factors that affect how bags will stack best such as how full the bag is, what type of product is in the bag, and how free flowing the material is within the bag. Several systems are available for shaping and flattening bags to ensure that they stack in the neatest possible way. Running a trial of your product on a palletising system before you commit to the capital expenditure is a very good way to determine what the best method is for palletising your product neatly.

4. Easy to Move/Re-site

Ensure that the system you choose can be easily moved. As your processes evolve over time, the last thing you want is to end up with a palletiser stuck in the wrong corner! There are modular palletising systems available; which means they can be quickly and easily re-situated and reconfigured to a different layout should the need arise. The modularity of these systems also allows you to adapt the palletising process over time by adding further processes at a later date such as pallet shrink wrapping, slip sheet feeding, automated pallet feeding, labelling etc. 

Downloadable Palletiser URS Template

To help you with choosing and specifying an automated palletising system we have created a downloadable Palletiser URS template.  This includes all of the key specifications that need to be considered when specifying a automated palletising system, and helps to ensure that the system will not only meet your current needs, but also your future requirements as well.

As you can see, when chosen wisely, an automated palletising system will not only provide the immediate benefits of increased reliability and throughput, but will also service your future requirements. With changing market demands and the ever-quickening pace of technology, it is important to ensure that the equipment you choose to invest in is flexible and adaptable enough to cope with these changes without the need for further significant investment.

One of the most adaptable and flexible palletising systems on the market is the Granta GA15 palletising system. It is fast and easy to program without the need for specialist programming skills. The easy programming software also includes automatic stack generation for an infinite variety of products, pallets and stack configurations. Having input the bag or box size you are palletising the optimum stack pattern is shown along with a variety of other stack patterns. All you have to do is simply select the stack pattern you require using the touch screen.

As the Granta GA15 palletising system is a modular system, it can also be simply and quickly reconfigured should your production requirements change. The modularity of the system also results in short lead times and a quick install time.

If you would like to discuss this guide in more detail, or would like further information on the Granta GA15 Palletising system, then please do get in touch on 01223 499488 or helpline@granta-automation.co.uk. 

contact us

Bag Palletiser

Bag Palletiser

Barrel Palletiser

Barrel Palletiser

Box Palletiser

Box Palletiser

Crate Palletiser

Crate Palletiser

Tray Palletiser

Tray Palletiser

Posted in Auto Palletiser, Automated Palletising, Company news, GA15 Palletiser, Granta Updates, Palletiser - Granta GA15 Palletiser System, Palletising, Robotic Palletising | Tagged , | Comments Off on Palletiser Buying Guide

Can Pallets Be Depalletised Automatically?

Posted on April 19, 2023 by Granta

Almost any type of product can be automatically depalletised, and the best method will vary depending on the type of product that is being depalletised and the speeds required. Depalletising of boxes or bags will often be done by a robot picking and placing the items one at a time, but for high-speed applications, such as depalletising bottles onto a production line, the product will usually be picked and placed as a complete layer to meet the speeds required.

There are many different reasons why a pallet may need to be depalletised, and some of the most common reasons are listed below:

  • Cross stacking product from Euro pallets to UK standard pallets to fit the UK distribution network and pallet storage system.
  • Depalletising items such as empty bottles or containers onto a production line ready for filling.
  • Depalletising boxes or bags off a pallet onto a conveyor ready for loading into a container for shipping.
  • Depalletising and repalletising of boxes or bags to get the correct quantity or stack pattern onto a pallet.

Cross stacking of bags or boxes from one pallet to another will typically be done by a robotic depalletising system and the system will usually be designed to suit your specific application and speeds.  The robotic arm will pick and place one item at a time and compensator tools may be used by the robot to allow for product variations. An angled alignment frame or conveyor system may also be needed to enable the product to be accurately re-positioned onto the new pallet.

Where product is being depalletised onto a production line or onto a conveyor for loading a container, the speeds required will determine the pick and place method. For slower speed applications items will be picked and placed individually, whereas for high-speed applications a complete layer, or row can be picked and placed onto the production line. Once the product is on the conveyor, it will then be orientated and separated as required by the production process.

Typically, a depalletising system will be built to suit your exact requirements, and can be designed to include pallet wrapping and labelling if needed.

Some of the key benefits to automatically depalletising product include:

  1. Improved efficiency: An automated depalletising system is more efficient than manually depalletising as it will not need to stop for breaks, holidays, etc., enabling you to run your depalletising process 24/7 if required.
  2. Improved safety: An automated system will remove the need for manual handing of product, and therefore reduce the risk of repetitive strain injuries occurring.
  3. Flexibility: Some automated depalletising systems have software that can be reprogrammed by your staff which gives you flexibility and enables you to use the system to depalletise a wide variety of products on the one system.

If you would like to discuss your depalletising application, feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk. 

contact us

Bag Palletiser

Bag Palletiser

Barrel Palletiser

Barrel Palletiser

Box Palletiser

Box Palletiser

Crate Palletiser

Crate Palletiser

Tray Palletiser

Tray Palletiser

Posted in Company news, GA15 Palletiser, Palletising, Robotic Palletising | Tagged , | Comments Off on Can Pallets Be Depalletised Automatically?