By Jake Reband, Sr. Account Executive at enVista
Optimisation across people, processes and technology is vital for increasing throughput and efficiency in the distribution center. Operations managers have a variety of options for achieving this, but one key area of opportunity is often overlooked: palletisation. We all know it’s best practice to automate the palletisation process with robotics, but few understand why.
I’ve been working with clients on robotic palletisation projects for nearly 25 years, and automation was around long before that. Strategising on palletisation is something that benefits all involved, but how?
What is Palletisation and Why it Matters
Palletisation is the final step an order goes through before it is handed off for shipment, and it is essential for optimising supply chain operations. It involves the strategic loading of products onto pallets to ensure safe, stable and efficient handling during storage and transport.
A standard pallet has a platform, a base and slots for inserting the forks of a forklift. Pallets speed up the loading and unloading of trucks that move and transport goods.
Most goods are palletised using manual or automated palletising machines. Automated palletising machines improve speed and accuracy while reducing the demand for skilled labour.
1. Increased Safety
Industrial robots frequently handle tasks that would be dangerous or strenuous for people to perform. The repetitive operator motions combined with heavy loads that are inherent in the palletisation process can lead to avoidable workplace injuries.
Safety devices and principles put in place with robotic palletisation systems are proven to reduce workers’ exposure to these often-risky processes.
2. Great Customisation Through Advanced Tooling
The traditional end-of-line palletisation process stacks identical components on a pallet. While that works fine for shipping in bulk, it doesn’t always suit the needs of retailers and end users who may not want a full pallet of one product. It also doesn’t meet the requirements of omnichannel retailers that often need to create mixed-load pallets, especially for food and beverage operations.
Robotisation and specialised software enable robotic stackers to automatically stack mixed loads on a pallet. Robot grippers and other end-of-arm-tooling customised for each specific application can automatically adjust to the size, shape and weight of the product to be stacked. Using barcode readers and cameras, robots can identify the size and shape of the product and automatically place it in the correct position on the pallet to create a stable stack.
If necessary, they can pick multiple boxes at a time, maximising system throughput. Specialised loading software can ensure the weight is distributed evenly across the pallet, with the heaviest items at the bottom.
3. Reduced Direct Labour Costs and Improved Efficiency
Automated palletising is faster and more efficient than manual labour. Most of these machines are unattended, and finished pallets typically move down a conveyor line until a forklift truck collects them. An automated palletiser creates a uniform pallet that’s more stable than one created manually.
Labour savings from automating the palletising process go beyond the removal of the operator from the box-handling process. With a centralised robotic palletisation system, multiple cells are building a variety of completed loads at the same time, vastly increasing efficiency with a lower operations load.
While automated robotic palletisers can require a significant investment, they provide a measurable return by working without a break over multiple shifts. Their operating costs over time are significantly lower compared to manual systems. Throughput is improved, allowing for faster response to orders and an increased turnaround.
4. Maximum Throughput
Automated palletising systems are designed to complete specific tasks repeatedly, with no breaks. They can run at maximum productivity around the clock, day after day and speed up the process of getting orders out the door.
5. Optimised Warehouse Space Utilisation
Automatic palletisers produce strong and stable uniform stacks. With an ability to mix products and use cardboard padding, a robotic palletiser can create pallets that conform to tight height, width and length requirements. This means it’s possible to maximize space utilisation in racking and delivery trucks by creating pallets that precisely fill the volumetric space.
Because the pallets are strong and secure, they can also be safely stacked in warehouses, freeing up valuable space. An added benefit of optimising the pallet size to suit the capacity of delivery vehicles is that they won’t move around during transportation, reducing the risk of product damage.
Robots aren’t subject to the same ergonomic and equipment restrictions as human operators. Systems can be designed to be space-saving, such as over a conveyor, while operators require space around the conveyor to safely perform the same task.
Choosing the Right Palletising Automation Partner
Warehouse operations are complex, and they become even more complex when automation is added to the mix. Selecting and implementing a successful automated palletising system requires considerable skill and experience and an in-depth understanding of your product mix, volume and facility layout.
With more than two decades of experience selecting and integrating supply chain technology, enVista has the expertise to integrate the physical and digital aspects of warehousing and manufacturing systems with state-of-the-art palletising solutions for omnichannel supply chains.
Our experts work with your teams to develop palletising solutions that can optimise your current operations and scale as the business grows. We partner with top equipment suppliers to obtain the optimal solution for your business.
Get Started with enVista
Is your throughput limited by an inability to palletise and ship your products? Automating the end-of-the-line palletiser with a robotic solution increases output and productivity. It also enhances employee safety and prevents product damage from unstable and collapsed pallets.
You can free up space and reduce headcount while improving order accuracy and on-time delivery. Warehouse automation software provides increased product visibility that helps improve order fulfillment.
Whether you’re just starting to think of automating your palletisation or upgrading existing equipment, enVista can design an automation solution that increases warehouse fulfilment capability and improves your bottom line.
Speak to us about robotic integration today.
