roll palletizer

Types of Roll Palletizers

Roll palletizers are large machines used to automatically stack products onto pallets or other containers. They are usually used in warehouses or logistics centers to decrease the amount of manual labor needed to stack products. Furthermore, they also help make stacking products more safely and faster.

• Hybrid palletizer:

  Hybrid palletizers combine features of both robotic and mechanical palletizing systems. They may use robotic components for product handling while employing mechanical systems for pallet stacking. Such palletizers offer flexibility, adaptability, and speed to accommodate diverse products and palletizing needs.

• Robotic palletizer:

  Robotic palletizers use robotic arms to pick products from a conveyor belt and stack them on pallets. The robotic arms are programmed to handle various product shapes and sizes. These palletizers offer flexibility and can be easily reprogrammed to change stacking patterns or accommodate new products.

• Layer palletizer:

  Layer palletizers automatically stack products onto pallets in layers or rows. They are primarily used for high-volume production lines dealing with flat or bundled items, such as boxes, bags, and rolled goods. Layer palletizers are suitable for accommodating multiple products simultaneously. Subsequently, they offer efficient handling and rapid palletizing speeds.

• Top mechanical palletizer:

  Top mechanical palletizers are systems that use robots to pick products and stack them on pallets, usually starting from the top. They use sensors and programmable controls to handle various product shapes and sizes. Moreover, they efficiently stack products onto patterns on pallets.

• Mixed palletizer:

  The mixed model combines mechanical and universal robots, especially for ecommerce and divide cases. It is a cell designed for pallets with a high mix of products while considering an affordable investment with the future to upgrade.

• Low-speed semi-automated roll palletizer:

  Low-speed semi-automated roll palletizers are systems that typically require manual intervention for product placement but offer automated palletizing for certain stages of the process. Moreover, they are more suitable for smaller production facilities or companies with lower product volumes.

• High-speed automated roll palletizer:

  High-speed automated roll palletizers are fully automated systems that provide continuous palletizing without manual intervention. They are more suitable for larger production facilities industrial lines with high product volumes.

• Layered roll palletizer:

  Layered roll palletizers are systems that stack products in layers onto pallets. They are more suitable for facilities dealing with flat or bundled items, such as boxes, bags, and rolled goods, and they offer efficient handling and rapid palletizing speeds.

Specifications and maintenance of roll palletizers

The pallet roll construction is designed to handle many rolls from different industries. Their specifications vary according to the model, manufacturer, and intended use. Here are some common specifications for a roll palletizer:

• Capacity

  It refers to the number of pallets or rolls a palletizing machine can handle. Palletizer capacity is typically measured per hour, e.g., a roll palletizer may have a capacity of 25 pallets/hour.

• Flexible systems

  They can handle different types, sizes, and shapes of products, e.g., rolls, cartons, etc. Some roll palletizers come with adjustable gathering arms and a speed change facility that allow them to handle products of various dimensions.

• Automation and control

  Automated roll palletizers come with control systems that allow for the programming and control of palletizing patterns, speed, and other parameters. These control systems may include touchscreen interfaces, programmable logic controllers (PLCs), and software for pattern selection and optimization.

• Dimension

  Roll palletizers come in different dimensions depending on the model and design. The height, width, and length of the palletizer will vary according to the machine's capacity and the size of the rolls it is intended to palletize.

• Power consumption and efficiency

  The power consumption of a roll palletizer refers to the amount of energy used by the machine while operating. It is typically measured in kilowatts (kW) or kilowatt-hours (kWh). Power consumption can vary depending on factors such as the size and capacity of the machine, the automation level, and the speed at which it operates.

Maintenance is crucial to ensuring the roll palletizers operate optimally. Here are some maintenance tips for automatic roll palletizers:

• Scheduled inspection and servicing:

  Manufacturers typically recommend routine inspections and servicing of palletizers. Ensure that maintenance personnel follow the recommended schedules and equipment guidelines. Regular maintenance will keep all machines in good condition for a long time.

• Lubrication:

  Automatic roll palletizers have several moving parts. Proper lubrication will prevent friction and ensure smooth movement. Ensure that the necessary parts are greased and oiled according to the maintenance manual.

• Cleaning:

  Regularly cleaning the machine will prevent the build-up of debris and dust. Use a soft cloth and non-abrasive cleaning products. Focus on the electronic components and sensitive parts of the machine. A clean palletizer will function better and have a longer lifespan.

Scenarios of roll palletizers

• Food and beverage industry:

  In the food and beverage industry, roll palletizers are commonly used to stack cartons, trays, or containers of food products onto pallets. They are used to efficiently stack products such as bottled drinks, canned goods, snack boxes, frozen foods, and more. Sanitary conditions are a must in all aspects of food and beverage. Roll palletizers can help maintain those conditions by ensuring that workers come into contact with products as little as possible, thereby reducing the risk of contamination. Automated stacking reduces the need for manual handling which in turn makes it easier to adhere to sanitary standards.

• Pharmaceuticals and healthcare:

  Roll palletizers are applicable in the logistics and distribution sector by efficiently stacking boxes, crates, or containers of goods onto pallets for further transportation and delivery. In addition, they can be used for case palletizing of items like tires, tools, machinery parts, and hardware in retail and logistics operations. Pharmaceuticals and healthcare industries rely heavily on roll palletizers to help sort and stack medicines and healthcare-related items like medical devices, equipment, and hygiene products. Roll palletizers ensure that healthcare professionals can always find what they need when they need it. Roll palletizers make it easy to keep stock organized and directionally accurate, which saves the stockroom, medical staff, and patients a lot of time and effort.

• Cosmetics and personal care:

  Roll palletizers can also be a huge help for small and large e-commerce businesses by efficiently stacking packages, boxes, or containers of products onto pallets for further fulfillment and distribution. Online retailers have many products to move. With roll palletizers, those products are moved quickly and easily so that customers don't have to wait long for their orders to arrive.

• Warehouse and distribution centers:

  Roll palletizers are the backbone of warehouse and distribution centers. They stack packages and boxes efficiently onto pallets for further shipment or storage. With roll palletizers, pallets can be moved quickly, easily, and accurately, making it a breeze to find what everyone needs when they need it—no more wasting time searching through the warehouse.

How to choose roll palletizers

Choosing the right roll palletizer for a specific application can impact productivity, efficiency, and cost. Several key factors should be considered when selecting a roll palletizer.

• Product characteristics analysis

  Examine the product features that need to be palletized, including size, weight, shape, and packaging configuration. Consider materials handling capacity, dimensions, and compatibility with the roller's design and features.

• Flow rate requirements

  Determine the desired flow rate or number of pallets per hour expected. Select a roll palletizer that can handle the required speed. Additionally, consider whether the machine needs to accommodate future expansion or increased production rates.

• Types of roll palletizer

  Assess different palletizers based on how they operate. Layer rolling palletizers are better for categorizing numerous items, while robotic ones afford flexibility with varied product shapes. Consider machine height and footprint based on available area.

• Integration and automation

  Consider the ability of the chosen palletizer to integrate other machinery, such as conveyors and packaging equipment. Select a roll palletizer with required control systems and automation levels for desired operational efficiency.

• Cost and ROI

  Assess the initial investment cost and operating expenses, including maintenance and energy consumption. Determine the expected return on investment (ROI) based on increased productivity, labor savings, and efficiency gains.

Roll palletizer FAQ

Q1: How do pallet roll mashers work?

A1: The pallet roll masher works by unloading the cartridge of rolls onto the pallets in the required quantity and pattern. It operatives by the same principle as the robotic palletizer but uses cylinders to push the rolls onto the pallet.

Q2: Are pallet roll masher necessary?

A2: The pallet roll masher is very helpful in reducing manual handling. They are cost-effective and efficient, especially when dealing with large volumes of pallets daily.

Q3: Who uses pallet roll mashers?

A3: Most industries that handle pallets and require them to be rolled at are majorly manufacturers, warehouses, distribution centers, and retail chains.

Q4: What is the future of palletizer machines?

A4: The future of the palletizer machines is very bright. With globalization and e-commerce, the demand for efficient handling and packing machines will continue to increase. It is expected that the market will grow at a compound annual rate.