Many people overlook the advantages of automated palletising. This article highlights the hidden benefits of automation and key factors to consider when investing in an automated palletising system.
Traditionally, stacking bags and sacks onto pallets was a manual task. However, this approach comes with several challenges, such as production slowdowns due to worker breaks and a high risk of repetitive strain injuries. These injuries can lead to extended employee absences and potential compensation costs, which can significantly impact a business. Additionally, manual palletising can restrict production efficiency and create bottlenecks in the workflow.
The Hidden Advantage
Many companies justify investing in automated palletising based purely on labour savings. However, they are often surprised by an unexpected yet significant benefit.
The key advantage? Simply installing a palletiser can boost the overall production line throughput by at least 140%!
Even with highly dedicated workers, manual palletising often leads to inefficiencies due to:
⦁ Time spent moving pallets to storage
⦁ Wrapping pallets
⦁ Completing paperwork
⦁ Breaks for meals or rest
⦁ Quick conversations between workers
⦁ Palletising at a slower rate than the production line’s capacity
While these delays may seem minor, they add up quickly and can have a significant impact on productivity.
Getting Started
With a variety of automated palletising systems available, choosing the right one is crucial. Below are some key factors to consider to ensure your investment meets both current and future needs.
Future-Proofing Throughput Capacity
Consider your current and future production needs. While your chosen system should meet your present throughput requirements, it should also allow for future growth. The last thing you want is for your palletiser to become a bottleneck as your sales increase. Ensure that your system is either scalable or has the capacity to handle future expansion.
Stack Quality
Properly stacked pallets are essential for product safety, easier transportation, and efficient storage. Different palletising methods impact stack quality, and factors like bag fullness, material type, and flow characteristics all affect how well bags stack. Some systems offer shaping and flattening features to enhance stack neatness. Running a trial with your product before committing to a system can help determine the best approach.
Ease of Use
A user-friendly system is essential. Can it be reprogrammed easily for different bag or box sizes? Some conventional palletisers require specialist programmers to make even minor adjustments. Choosing a system with intuitive software enables your staff to modify stacking patterns without extra costs or delays. Automated stack generation software is also beneficial, allowing you to select stacking patterns without manual configuration.
Flexibility and Mobility
Ensure your palletising system can be easily moved or reconfigured as your operations evolve. Modular palletising systems offer flexibility, allowing you to reconfigure layouts or integrate additional features like shrink wrapping, slip sheet feeding, and automated pallet feeding.
Test Before You Buy
To ensure a seamless integration, test your product on a palletiser before purchasing. Small variations in product shape, size, or material flow can impact stacking effectiveness. Many automation companies offer free trials to help you determine the best solution.
Seamless Integration with Existing Processes
Working with a provider experienced in machinery integration is key. They can ensure your palletiser is efficiently linked to your production line. A reliable automation company will conduct a site visit, provide expert guidance, and offer 3D CAD drawings to optimize the system’s placement. Depending on your setup, a single robotic palletiser may even handle multiple production lines simultaneously.
Calculating ROI
Automated palletising systems typically offer a fast return on investment. Beyond reducing labour costs, they keep production running during breaks, increasing overall efficiency. Some automation providers offer tools to calculate ROI, including an automation project payback calculator and an intangible benefits calculator, helping you assess the full impact of automation.
Conclusion
A well-chosen automated palletising system delivers immediate benefits such as increased reliability and throughput while also preparing your business for future demands. In an evolving market, investing in a flexible and adaptable system ensures long-term efficiency and cost savings.
One of the most versatile systems available is the Aurora GA15 Palletising System. Designed for ease of use, it requires no specialist programming skills and features automatic stack generation for various product types and configurations. Its modular design allows for quick reconfiguration as production needs change, ensuring long-term adaptability.
Things to Consider Before Purchasing an Automated Palletizing System:
⦁ Has a trial been conducted to test the system’s effectiveness?
⦁ Can it integrate seamlessly with your existing production process?
⦁ Has the ROI been calculated, including the hidden benefits?
⦁ Can the system accommodate both current and future throughput needs?
⦁ Will it ensure neatly stacked pallets?
⦁ Can staff easily program it for different product sizes and stack patterns?
⦁ Is it easy to move, reconfigure, and expand if needed?
By carefully evaluating these factors, you can make an informed decision and maximize the long-term value of your investment in automated palletising.
