Packing and palletising lines – chain conveyors
The heart of every system is a robot…
Automatic palletising system
At the heart of every system there is a robot with a dedicated gripper adapted to the needs of a given line. Lean-Tech’s automation and design engineers take an individual approach to each solution, designing the objectives in a way that optimises the speed, range, and working capacity of the arm. Depending on the analysis of the solution, the robot can grab a single workpiece (package, bag, container), as well as a set of several pieces, a stack or even several full layers of palletised goods. An important issue is therefore both the proper selection of the robot as well as power supply equipment, stacking and preparing workpieces for palletisation.
It should be remembered that the gripper is often a separate device which performs many functions in the whole palletising process. In addition to the basic task of gripping and moving workpieces, we offer our customers solutions that allow the operation of the entire line. Lean-Tech can also equip the gripper with pneumatic modules delivering layer spacers, mechanical manipulators of load units (feeding pallets to a given line), or advanced vision and scanning systems, owing to which it is possible to control the functions of the robot depending on the programmed type of detection.
Robotised palletising systems are designed in a safe way and at the same time maintaining the highest standards. Each design is subject to hazard analysis and risk assessment.
Due to the requirement for individual approach to design, operation, and service, Lean-Tech provides comprehensive technical solutions, clear and transparent operating documentation, and offers a series of training courses for operators and maintenance services. Commissioning takes place with the full support and assistance of engineers during first launch of each system.
Automatic palletising system
A well-designed automatic palletising system combines technological and pallet transport systems with the simultaneous use of additional equipment. The robot’s objective is therefore a complex combination of the following:
When closing the automatic “technological chain” described above, the transport line is usually equipped with an automatic wrapping machine and/or a strapping machine, and a labelling device. Lean-Tech is a supplier and integrator of comprehensive solutions for palletising systems for transport and storage.
of the PAL or NJ(Shelf) type
individually designed for a given solution
the so-called “feeder”, which supplies products in individual or collective packaging to the robot’s operating area
a device for stacking and preparing the workpieces for correct feeding under the gripper
pallet magazine and connected line supplying the system with main transport units
Pallet pick-up conveyor system that transports the palletised units outside the robot’s cell
The stacking of products on a pallet can be carried out successfully by means of robots and machines. This solution optimizes the efficiency of palletising, while at the same time making it possible to direct the capacity of employees to other tasks.
One of the most frequently automated production processes is palletising. Industrial robots used for this purpose enable faster, more precise and continuous palletising of workpieces, often serving more than one production line at a time. The palletiser can also feed pallets, stabilize individual layers of goods with spacers, pack components, so that it is possible to fully automate the palletisation process in virtually any company.mie.
Pick-to-box – Chain conveyors
Moving around takes up most time of the employees who deal with picking orders. Depending on the warehouse, it takes up to 35% to 50% of the working time. A way to increase efficiency in this area is to divide the warehouse into zones and to use a chain conveyor to transport goods for transport among different zones. The shipping item travels on a conveyor and is dropped in the sectors where the remainder of the order to be picked is located. With this solution, an employee picking an order and assigned to one of the zones only works in this area, which significantly reduces the distance he has had to travel.
The division of functions in the warehouse saves a lot of time. Chain conveyors transport goods between the picking zone, packing zone and the shipping zone, where they automatically sort the transport packaging into directions or courier companies. Many other devices can be integrated into the conveyor line, such as flow scales, labelling machines, automatic carton folding and closing machines, elevator and carousel racks or pick-to-light systems.
If it is necessary to complete orders within the shortest possible time, a consolidation station is the ideal solution. It is a system consisting of conveyors and carousel racks. The order is divided into parts and assembled in zones for the internal transport containers. Containers flow from the zones in any order to the consolidation zone, where all elements related to one order are stored on adjacent shelves in a carousel rack. Once all the items have been picked, they are transferred to the packing area. The packaging employee receives the complete order and packs it into shipping cartons.
Carousel and lift racks
Carousel and lift racks are widely used in distribution. This solution ensures high picking efficiency (up to 200 lines per hour) with high work ergonomics. Automatic shelving units are mainly used for picking small products. They can be stored up to a height of 8m. This means that a large number of goods can be stored within a small space. Additionally, one employee can operate a set of 3-4 devices, which improves the process of product picking management.
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