Fulfillment/Logistics Trends
Most Read
Most E-mailed
E-mail Article
Print Article
Considerations When Planning a Palletizing Operation
Understanding your technology options for stacking and securing the cases and coding the load in the DC
June 10, 2009 — More than 2 billion pallets are in use every day, dominating the landscape in most warehouses and distribution centers, while serving as the interface between the product and the mode of transportation.
In September 2008, the demand for pallets was forecasted to increase, with experts predicting that warehousing will show the most rapid gain, rising 6 percent per year through 2012. Although these figures were before the dramatic affects of the recession and the collapse of the markets, the fact remains: more than ever before, companies will look for ways to increase productivity, minimize manpower, and save money with effective palletization.
Palletization is the task of taking cases and stacking them in layers on pallets for storage and/or transportation. It's how the stacking is done, whether manually, automatically or semi-automatically, that varies from warehouse to warehouse. The amount and type of product being moved often determines which mode of palletizing will be used.
Assessing the Modes
Manual Palletizing is the most basic and also the most widely used method. Typically, workers remove cases from a conveyor line or an existing pallet load and stack them onto a pallet. The pallet resides on a pallet jack, forklift or the floor while being packed. The cases can either be stacked straight up (column stacked) or staggered (interweaving) in order to increase stability and sturdiness.
Semi-automatic Palletizing is used when case weight is a factor and workers are subject to back strain injuries, often resulting from manual palletizing. With a semi-automatic system, a conveyor delivers product to an operator who arranges the cases in layers on a variable height lift table. The operator utilizes a push button or a foot switch to raise and lower the load to the appropriate ergonomic height. This method increases efficiency and decreases back and shoulder injuries. Additionally, outfitting the variable height lift table with a rotating turntable also introduces efficiency and ergonomic benefits. With this feature, after all of the layers are stacked onto the pallet and it is ready for stretch wrapping, an operator can stay stationary and apply the wrapping as the pallet rotates in front of him or her.
Automatic Palletizing provides the fastest, most efficient and most ergonomically friendly method of palletizing. Currently, there are two common methods of automatic palletizing: conventional and robotic systems.
With the conventional method, cases travel along a conveyor and are delivered to a layer-building table, where the cartons are automatically turned and interlocked into the appropriate pattern. The pattern closely resembles a jigsaw puzzle and follows the specification that has been programmed into the equipment, thus eliminating human error. Once a layer is built, it can slide onto a stripper plate (sometimes referred to as a deck or apron); the stripper plate retracts horizontally, dropping each layer of cases onto a pallet load. This method is much like the old magic trick of pulling a tablecloth off without disturbing the dishes. Conventional automatic palletizers offer a broad range of speeds, with rates ranging anywhere from 10 to 200 cases per minute.
In September 2008, the demand for pallets was forecasted to increase, with experts predicting that warehousing will show the most rapid gain, rising 6 percent per year through 2012. Although these figures were before the dramatic affects of the recession and the collapse of the markets, the fact remains: more than ever before, companies will look for ways to increase productivity, minimize manpower, and save money with effective palletization.
Palletization is the task of taking cases and stacking them in layers on pallets for storage and/or transportation. It's how the stacking is done, whether manually, automatically or semi-automatically, that varies from warehouse to warehouse. The amount and type of product being moved often determines which mode of palletizing will be used.
Assessing the Modes
Manual Palletizing is the most basic and also the most widely used method. Typically, workers remove cases from a conveyor line or an existing pallet load and stack them onto a pallet. The pallet resides on a pallet jack, forklift or the floor while being packed. The cases can either be stacked straight up (column stacked) or staggered (interweaving) in order to increase stability and sturdiness.
Semi-automatic Palletizing is used when case weight is a factor and workers are subject to back strain injuries, often resulting from manual palletizing. With a semi-automatic system, a conveyor delivers product to an operator who arranges the cases in layers on a variable height lift table. The operator utilizes a push button or a foot switch to raise and lower the load to the appropriate ergonomic height. This method increases efficiency and decreases back and shoulder injuries. Additionally, outfitting the variable height lift table with a rotating turntable also introduces efficiency and ergonomic benefits. With this feature, after all of the layers are stacked onto the pallet and it is ready for stretch wrapping, an operator can stay stationary and apply the wrapping as the pallet rotates in front of him or her.
Automatic Palletizing provides the fastest, most efficient and most ergonomically friendly method of palletizing. Currently, there are two common methods of automatic palletizing: conventional and robotic systems.
With the conventional method, cases travel along a conveyor and are delivered to a layer-building table, where the cartons are automatically turned and interlocked into the appropriate pattern. The pattern closely resembles a jigsaw puzzle and follows the specification that has been programmed into the equipment, thus eliminating human error. Once a layer is built, it can slide onto a stripper plate (sometimes referred to as a deck or apron); the stripper plate retracts horizontally, dropping each layer of cases onto a pallet load. This method is much like the old magic trick of pulling a tablecloth off without disturbing the dishes. Conventional automatic palletizers offer a broad range of speeds, with rates ranging anywhere from 10 to 200 cases per minute.
RSS Feeds
