Increasing Throughput & Efficiency with Automated Palletizing - Transforming Food & Beverage Operations with Collaborative Robots (Part 2)

Increasing Throughput & Efficiency with Automated Palletizing 

Automated palletizing is a game-changer for manufacturers looking to improve throughput and efficiency in their operations. By integrating advanced automation technology and collaborative robotic systems, like those from Universal Robots, companies can streamline the process of stacking products onto pallets - leading to multiple benefits. 

One of the biggest advantages of using collaborative robots in palletizing is the ability to increase product yield while maintaining product quality. Manual palletizing is often a bottleneck in production, slowing down output and creating inconsistencies. With cobots, businesses can ensure steady, repeatable operations that keep up with production demands. 

How Cobots Enhance Efficiency 

1. Faster Operations - Consistent Speed & Continuous Operation:

Automated palletizers can work at high speeds, performing repetitive tasks quickly and consistently without breaks. This leads to faster throughput compared to manual labor, which is often slowed down by human limitations. 

Automated systems can run continuously, even during off-hours, without the need for shifts or downtime, thus increasing the overall throughput. 

2. Reduced Labor Costs – Less Manual Labor & Minimized Errors:

By automating the palletizing process, businesses can reduce the number of workers required for repetitive tasks. This not only cuts down on labor costs but also reallocates human resources to more complex tasks that can't be automated. 

Manual palletizing can lead to errors in stacking, such as improper load distribution or misplacement. Automation reduces these human errors, leading to a more reliable process. 

3. Optimized Space Utilization – Precise Palletizing & Better Handling of Products:

Automated systems can stack products in the most efficient manner, ensuring that pallets are fully loaded with minimal empty space. This maximizes storage capacity and optimizes transportation logistics, making the whole process more cost-effective. 

Robots and automated systems can be programmed to handle products of varying shapes and sizes with precision, reducing the risk of damage during the palletizing process.

4. Increased Worker Safety - Reduced Physical Strain on Workers & Minimized Risk of Injury:

Palletizing can be a physically demanding task, especially with heavy or awkward items. The consistent lifting, twisting, bending, & sliding of product with the human body takes a toll.

Automation takes over these strenuous tasks, reducing the risk of worker injuries, increasing safety, and enabling workers to focus on more strategic tasks. 

5. Higher Throughput per Worker - Productivity Gains & 24/7 Operation:

With automated palletizers, fewer workers can manage larger volumes of products. The system's speed and efficiency allow a small team to oversee the operations, which in turn boosts overall productivity. 

Automation doesn't need to adhere to the typical work schedule, allowing for continuous operation and ensuring that throughput is maximized at all times. 

6. Built-In Quality Control:

Automated systems can also include built-in quality checks to ensure that the stacking or packaging process meets the desired specifications, improving the quality of the final product or pallet. 

7. Data Integration and Analytics – Process Monitoring & Predictive Maintenance:

Many automated palletizing systems are integrated with monitoring software that tracks performance in real-time. This enables continuous improvement by identifying bottlenecks or areas of inefficiency that can be addressed promptly. 

Automation can also incorporate predictive maintenance, ensuring that machines are serviced before they fail, which minimizes downtime and keeps the system running at optimal efficiency. 

8. Scalability – Easy Scaling:

As demand increases, automated systems can be scaled up more easily than manual labor.

Additional robots or palletizing stations can be added to handle increased volumes without requiring a significant reorganization of the workforce. 

9. Consistency - Repeatable Precision:

Automation ensures that the palletizing process is consistent every time. Whether it's the orientation of a product, the number of layers, or the specific stacking pattern, automated systems provide repeatable precision that reduces variations in the final load

10. Seamless Integration with Other Systems:

UR cobots can be programmed to work with existing conveyor systems, creating a streamlined palletizing process.

Real-Life Example 

A Dairy Producer implemented a Universal Robot UR16e model cobot for palletizing yogurt packs. This automation allowed them to increase their production rate by 25%, eliminate downtime caused by worker fatigue, and improve overall supply chain efficiency. 

Beyond improving production rates, cobots also help standardize operations. With human labor, variations in performance can lead to product misalignment and inconsistent stacking, leading to damaged goods and inefficiencies in logistics. By implementing cobots, the Dairy Producer achieved uniform pallet loads, reducing transportation-related product loss and optimizing their supply chain for better customer satisfaction.

By adopting a Palletizing Solution, manufacturers give themselves the ability to optimize operations while setting the stage for continued growth.  Automation doesn’t have to be intimidating—it can be a strategic, step-by-step process with significant advantages and benefits. 

In conclusion, automated palletizing drives improvements in throughput and efficiency by increasing speed, reducing human error, lowering labor costs, and offering a safer, more adaptable solution for businesses. With the added benefit of real-time analytics and scalability, it’s clear that automation is an essential tool for businesses looking to stay competitive and agile in the marketplace. 

INTERESTED IN EXPLORING AUTOMATION FOR YOUR END-OF-LINE?

If you are interested in learning more insights on Automated Palletizing and/or specific technologies used, such as Universal Robots collaborative robots or the turnkey Palletizing Solution from Robotiq , The Knotts Company would be happy to assist!   

Our in-house Knotts Automation & Robotic Team would be happy to set up a no-charge Application Automation Review.  Upon our initial phone call, we will review all projection information, including current process, goals, estimated output now vs. numbers upon implementation, products being used, weight of product, pallet size, stacking height, etc.  We would then arrange an on-site visit to your facility to see your manual labor process in-person, check product material, see current layout, and take measurements to ensure the correct equipment can be suggested (and fit!) as a solution for your needs. 

LEARN MORE HERE:  https://www.knottsco.com/services/palletizing-solutions 

To get started, please reach out to us at The Knotts Company!

LET’S MAKE YOUR OPERATIONS MORE EFFICIENT, PROVIDE HIGHER OUTPUT, & PERMANENTLY RESOLVE END-OF-LINE PRODUCTION INSTABILITY!