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The cobot palletisers have transformed manufacturing in recent years by delivering an efficient and adaptable solution for repetitious palletising tasks. These collaborative robots, or “cobots,” work alongside human operators, increase productivity while reducing workplace injuries associated with manual labour. But what exactly are cobot palletisers, and what benefits and challenges do they bring? In this article let us learn both pros and cons of having one.

What is a Cobot Palletiser?

A cobot palletiser is a type of collaborative robot designed to automate the process of stacking items—such as boxes, bags, or other packaged goods—onto pallets in warehouses and production facilities. Unlike conventional robotic systems that often require dedicated safety enclosures and complex programming, cobot palletisers are engineered to operate safely in close proximity to humans.

With integrated safety features, they can function at industrial palletising speeds while maintaining a safe working environment. This makes them an ideal solution for businesses with limited space that need to boost operational efficiency.

Cobot palletisers typically use vacuum or paddle grippers to pick products from a conveyor belt or other feeding systems and place them onto pallets in a pre-determined stacking pattern. Designed for ease of use, these robots often feature intuitive interfaces, allowing operators to adjust settings without specialised training. Their plug-and-play functionality also simplifies integration into existing workflows, reducing setup time and minimising the need for extensive programming knowledge.

Advantages of Cobot Palletisers

1. Increased Productivity

Cobot palletisers can operate continuously without breaks, maintaining a steady workflow without the fatigue or downtime associated with human labour. This ability to work around the clock significantly improves production rates, shortens cycle times, and increases overall throughput.

2. Enhanced Safety

Safety is a key advantage of cobot palletisers. Equipped with advanced sensors, these robots detect nearby workers and adjust their speed or stop altogether to prevent collisions. Unlike traditional industrial robots that require protective barriers, cobots can function safely in shared workspaces. When integrated with additional safety measures such as area scanners or guarding, they can operate at full industrial speeds and switch to a slower, safer mode if necessary.

3. Flexibility and Adaptability

Cobot palletisers are highly adaptable and can be reprogrammed to handle different products, packaging formats, and stacking patterns. This makes them particularly valuable in industries with frequently changing production needs. With user-friendly programming interfaces, businesses can quickly modify operations without requiring costly reprogramming or technical expertise.

4. Improved Workplace Ergonomics

By taking over repetitive and physically demanding tasks, cobot palletisers help reduce strain-related injuries among workers. Instead of lifting heavy items or repeatedly bending and twisting, employees can focus on higher-value tasks like quality control, monitoring systems, and process optimisation, leading to a more ergonomic and satisfying work environment.

5. Space Efficiency

Unlike bulky industrial robots that require large safety zones, cobot palletisers have a compact footprint and can be integrated into existing production lines without extensive modifications. This makes them an excellent choice for businesses with limited workspace, allowing them to optimise floor space while benefiting from automation.

Challenges of Cobot Palletisers

1. Speed Limitations in Collaborative Mode

While cobots are designed for safe human interaction, safety regulations require them to operate at reduced speeds in collaborative mode. This can limit their efficiency in high-speed production environments. However, businesses can install additional safety measures, such as physical guarding or area scanners, to enable cobots to operate at higher speeds while complying with safety standards.

2. High Initial Investment

Despite being more cost-effective than traditional robotic systems, cobot palletisers still require a significant upfront investment. Businesses must consider costs related to the cobot itself, integration, safety systems, and any necessary infrastructure modifications. For small and medium-sized enterprises (SMEs), these expenses can be a financial challenge, especially if the return on investment (ROI) is not immediately apparent.

3. Limited Payload and Speed

Cobot palletisers are generally designed for light- to medium-weight applications. While they work efficiently for smaller products, they may struggle with heavier loads or high-throughput environments. Traditional industrial robots, with larger payload capacities, can lift entire layers of products at once, making them a better fit for large-scale operations. Businesses should assess their specific palletising requirements before opting for a cobot solution.

4. Programming and Technical Expertise

Although cobots are designed for ease of use, some systems still require technical expertise for programming and configuration. Choosing a model with intuitive programming software and automatic stack pattern generation can simplify product changeovers and reduce downtime.

5. Integration Challenges

Seamless integration into an existing production line can be complex, particularly if the current infrastructure is not compatible with cobot technology. Cobots must work in sync with conveyor belts, sensors, and other machinery, which may require additional engineering and customisation. Without proper planning, integration challenges can lead to delays and inefficiencies.

6. Dependence on Human Operators

Despite their automation capabilities, cobot palletisers still require human intervention for tasks like material loading and pallet changeovers. If workers are unavailable or slow to respond, this can lead to downtime and inefficiencies in the production process.

Conclusion

Cobot palletisers provides a compelling automation solution, combining space efficiency, cost-effectiveness, and ease of programming. Their ability to enhance productivity, improve workplace safety, and adapt to changing production needs makes them an attractive investment for many industries. However, businesses must weigh their potential limitations—such as payload capacity, speed constraints, and integration complexity—before making a decision.

By carefully evaluating operational requirements and considering long-term benefits, manufacturers can determine whether a cobot palletiser is the right fit for their automation strategy.

Optimising warehouse operations allows businesses to be more efficient in today’s fast-moving and highly competitive business environment. Warehouse operations must continuously evolve to meet the growing demand for accuracy, speed, and cost-effectiveness. While manual labour has traditionally been a fundamental aspect of warehouse management, it is increasingly becoming a limiting factor due to inefficiencies, high costs, and safety concerns. Applying automation and technological advancements in business landscape is crucial for maximising productivity and ensuring operational sustainability in long-term.

The rapid technological innovations are transforming warehouse operations by streamlining tasks, improving accuracy, and reducing operational costs. This article highlights key strategies for minimizing manual labour, with a focus on automation, robotics, and digital solutions. Among these, automated palletizing emerges as one of the most transformative solutions, significantly enhancing material handling efficiency.

1. Automated Palletizing: Revolutionizing Material Handling

Automated palletizing is one of the most impactful advancements in warehouse automation. Traditionally, palletizing—the process of stacking products onto pallets for storage or shipment—has been a labour-intensive and physically demanding task requiring precision and repetitive effort. Workers must manually lift, move, and arrange items, which can lead to fatigue, injuries, and inconsistent results.

By leveraging robotic arms, advanced software, and mechanical systems, automated palletizing minimizes human intervention while significantly increasing efficiency and accuracy.

Key advantages include:

Enhanced Speed and Productivity: Automated palletizing systems operate continuously without fatigue, achieving faster and more consistent performance compared to manual labour.

Improved Workplace Safety: Automating palletizing reduces the need for workers to handle heavy loads, minimizing the risk of musculoskeletal injuries.

Greater Precision and Consistency: Robotic palletizing ensures uniform and stable pallet stacks, reducing product damage during storage and transportation.

Scalability and Flexibility: These systems adapt to varying product sizes, shapes, and packaging, making them highly versatile.

Long-Term Cost Savings: Despite the initial investment, automated palletizing leads to significant labour cost reductions and improved operational efficiency.

For businesses handling large product volumes, implementing automated palletizing is a strategic decision that enhances operational quality while reducing dependence on manual labour.

2. Automated Guided Vehicles (AGVs) & Autonomous Mobile Robots (AMRs): Transforming Internal Logistics

The adoption of Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) is revolutionizing intra-warehouse transportation. These robotic systems efficiently transport goods, eliminating the reliance on manually operated forklifts and pallet trucks.

AGVs navigate warehouses using predefined paths guided by sensors, magnetic strips, or laser systems.

AMRs utilize artificial intelligence and mapping technology to dynamically adjust routes based on real-time warehouse conditions.

The advantages of AGVs and AMRs include:

Continuous Workflow: Operating 24/7 without breaks, these robots enhance material flow and reduce lead times.

Enhanced Safety: Equipped with advanced sensors, AGVs and AMRs avoid collisions and navigate safely around obstacles.

Lower Labour Costs: Automating material transport reduces the workforce needed for goods movement.

Scalability and Adaptability: Unlike fixed conveyor systems, AGVs and AMRs can be reprogrammed to accommodate changes in warehouse layouts.

By reducing manual transportation efforts, AGVs and AMRs enhance speed, accuracy, and safety in warehouse logistics.

3. Conveyor and Sorting Systems: Streamlining Goods Movement

Automated conveyor and sorting systems play a vital role in optimising warehouse efficiency. These systems automatically transport, sort, and route products, significantly reducing manual handling.

Modern conveyor systems integrate intelligent controls and sensors to enhance operational accuracy.

Key benefits include:

Faster Processing: Automated conveyors process thousands of items per hour, greatly improving throughput.

Reduced Manual Dependence: By automating material movement, workers can focus on more value-added tasks.

Higher Accuracy: Automated sorting minimizes errors, especially during high-volume operations.

Optimised Picking and Packing: When integrated with Warehouse Management Systems (WMS), conveyors streamline product routing for picking and shipping.

These systems are particularly beneficial for high-volume distribution centers requiring fast and precise product handling.

4. Warehouse Management Systems (WMS): Digital Optimisation for Inventory Control

A Warehouse Management System (WMS) is an essential tool for reducing manual labour in warehouse operations. It provides real-time tracking of inventory from arrival to shipment, minimizing the need for manual stock checks and ensuring accurate data flow.

A WMS enhances efficiency by:

Automating Inventory Tracking: Utilizing barcode scanning, RFID technology, and IoT sensors to maintain real-time stock updates.

Optimising Picking Routes: Designing efficient pathways to reduce retrieval time.

Integrating with Automation: Synchronizing with robotic systems, AGVs, and AS/RS (Automated Storage and Retrieval Systems) to further minimize human intervention.

Implementing a WMS ensures more accurate inventory management while reducing manual tasks and operational bottlenecks.

5. Pick-to-Light and Put-to-Light Systems: Simplifying Order Fulfillment

Pick-to-light and put-to-light systems are innovative solutions designed to improve efficiency in warehouses managing diverse inventories. These systems use light indicators to guide workers in picking and placing items, streamlining the fulfillment process.

Benefits of these systems include:

Higher Accuracy: Reduces picking and placement errors.

Faster Order Processing: Illuminated signals enable quick identification of items.

Reduced Training Requirements: User-friendly technology allows employees to adapt quickly, cutting down training time.

By leveraging visual guidance, pick-to-light and put-to-light systems enhance efficiency and accuracy in warehouse operations.

6. Collaborative Robots (Cobots): Enhancing Human-Robot Interaction

Collaborative robots (cobots) are a groundbreaking addition to warehouse automation, designed to work alongside human employees rather than replacing them. Unlike traditional industrial robots, cobots feature safety sensors that allow them to operate in shared spaces without risk.

Cobots are commonly used for:

Picking and Packing: Assisting in repetitive tasks to reduce physical strain on workers.

Palletizing: Automating the placement of products onto pallets.

Workflow Optimisation: Enhancing overall warehouse efficiency by complementing human capabilities.

By integrating cobots into warehouse operations, businesses can strike a balance between automation and human expertise, optimising efficiency while maintaining flexibility.

Conclusion

As warehouses face increasing demands for speed, precision, and scalability, automation is no longer optional—it is a necessity for staying competitive. By adopting advanced technologies such as automated palletizing, AGVs, AMRs, conveyor systems, WMS, and cobots, businesses can significantly reduce labour costs, enhance accuracy, improve safety, and optimise overall efficiency.

Embracing automation ensures not only immediate advantages but also long-term sustainability, positioning warehouses for future growth in an ever-evolving industry. Embracing these advancements will be the key to maintaining a competitive edge in modern logistics and supply chain management.

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.

Learn Efficient Stretch Film Strategies for Cost Reduction

Maximize your budget by reducing packaging expenses and it starts with choosing the right stretch film. Selecting a film that aligns with your specific needs enhances efficiency while keeping costs in check. The right film minimizes waste and ensures stable loads during transport and storage.

Pick the Right Stretch Film

First, you need to evaluate the size, type, and stability of your loads. These aspects influence the film choice—hand stretch wrap is perfect for smaller, lightweight loads, while pallet stretch film is better suited for heavier shipments. The key is to maintain stability without using excess material.

The volume of packaging and load characteristics should also guide your choice between hand wrapping and machine wrapping. Hand-wrapping with stretch film rolls works well for small-scale operations or irregularly shaped items, whereas machine wrapping is optimal for high-volume warehouse applications.

Effective Strategies to Reduce Packaging Costs

Cost-efficient packaging begins with maximizing stretch film efficiency. Implementing the right practices can lead to substantial savings while ensuring load security. Here are practical tips to optimize your packaging process:

1. Carefully Select the Right Film Gauge

Choosing the appropriate film thickness (gauge) significantly impacts cost savings. Thin films, particularly pre-stretch options, reduce material usage without sacrificing load stability. Pre-stretching maximizes film yield, allowing you to wrap more pallets with less material. Lighter loads benefit from thinner films, while heavier items may require a slightly thicker gauge.

Aurora’s Technoplat 3000 is an excellent choice. It provides optimal stretch, reducing material usage while ensuring secure loads. Using its remarkable features it improves application efficiency and reduces operator fatigue.

2. Optimize your Wrapping Techniques

Proper film application prevents waste and enhances load security. Best practices include:

Applying the right number of layers for load stability.

Aligning film edges to maximize coverage.

Wrapping tightly but avoiding excessive force to prevent breakage.

3. Streamlining the Packaging Design

Optimizing packaging design helps cut costs by reducing unnecessary material use. Consider these strategies:

Evaluate Current Packaging – Identify areas where film consumption can be minimized, such as switching to pre-stretch films like FlexLite.

Use Alternative Materials – Combining stretch film with corner boards can enhance load stability while lowering film usage.

Reduce Void Space – Ensure compact and properly stacked loads to eliminate excess packaging and improve stability.

4. Leverage Supplier Partnerships

Negotiating with suppliers can lead to considerable savings. Key approaches include:

Bulk Purchasing – Buying in larger quantities often unlocks volume discounts, particularly for warehouses with consistent demand.

Long-Term Contracts – Securing fixed rates protects against price fluctuations and guarantees a steady supply of high-quality stretch film.

Establishing strong supplier relationships allows for better collaboration and access to innovative solutions.

5. Track and Analyze Film Usage

Monitoring stretch film usage is essential for long-term cost reduction.

Measure Film Consumption – Use data to track usage patterns and pinpoint inefficiencies.

Set Reduction Goals – Establish achievable targets for minimizing film consumption and review progress regularly.

Employing useful tools like fatigue-fighter dispensers ensures uniform application, simplifying tracking and optimization efforts.

Conclusion

To wrap things up, The pre-stretch films deliver an eco-friendly alternative by cutting down on material usage while maintaining load security. Implementing these cost-saving tips leads to more efficient operations and contributes to a greener, more sustainable environment.

Reducing material consumption helps minimize waste, supporting sustainability initiatives and lessening environmental impact. Efficient stretch film usage not only reduces costs but also improves overall packaging operations.

A production process normally flows from product design, engineering, prototyping, manufacturing, and last but not least, packaging. First impressions are very important, and your packaging is often a consumer’s first introduction to your product. At its most fundamental level, product packaging serves to protect the integrity of the product inside. Another key functional aspect of product packaging is to promote and display the product within.

The perfect packaging protects and shields your pallets from dust, moisture, UV, tampering, and much more. Although wrapping pallets may not seem like a technical or advanced concept, hand stretch wrapping may cause inconsistencies that require the process to start over, wasting wrap and causing production downtime. To further streamline your process, an automatic stretch wrapping machine is the solution to improve efficiency without sacrificing quality. 

Here are the five benefits of incorporating an automatic stretch wrapping machine into your production processes. 

Protection of Your Products 

Dust, dirt, or moisture can damage packaging throughout the transportation and storage process. Companies often focus on packaging presentation and protection within their process facility only. However, their product can incur significant damage from the logistics chain resulting in brand damage.  A good stretch wrapping machine will help ensure your brand presentation and reputation are preserved right through to the customer. 

Save Time and Energy 

Manually wrapping pallets, boxes, and other products can prove tedious and time-inefficient, impacting the business’ productivity, especially if consistent packaging is to be expected. However, wrapping your pallets for storage and transportation with an automatic stretch wrapping machine will allow your employees to put their saved time and energy toward maximising other business processes. 

Improved Safety of Your Employees

It is estimated that around 20% of all forklift accidents occur when the operators are on the floor, and not inside the forklift. By using an automatic stretch wrapping machine, you have implemented a safety measure on its own. The machine will ensure that the packaged pallets are safe and ready to be transported by the forklift and truck. 

Save Money on Film Costs 

Although investing in an automatic machine may seem expensive at the start, one of the greatest long-term advantages of automatic wrappers is cost savings. This is made possible by the two-film thread roller system that is utilised by automatic stretch wrappers, in which the second roller operates at a higher speed than the first to stretch the film. As a result, the film’s tensile strength increases and reduces the overall cost. Not only that, but an automatic machine is far more likely to be consistent and tidy than a manual process, which reduces your risk of having to repeat the packaging process and wastes time, film, and energy. 

Boost Productivity

Production process streamlining has always been an important goal for most manufacturing businesses. An automatic stretch wrapping machine allows your business to maximise efficiency without sacrificing the quality of the finished products. Through the placement of the pallet on a conveyor or on a wrapper plate, the wrapping starts and stops automatically, allowing your company to accomplish more in less time. With every machine, the speed and capacity are different, depending on the type of product you are looking to package. 

In Conclusion

Although an automatic pallet wrapping machine may present itself to be a large upfront investment, its long-term advantages certainly outweigh its cost. With that being said, choosing a specific automatic stretch wrapping machine that fulfills your production needs can be challenging to do on your own. 

At Aurora Process, we are happy to assist you in unlocking your Process Potential, as we aim to help businesses to take advantage of everyday automation with confidence through machinery automation & robotics. We are specialists in end-of-line process equipment, such as bag filling machine and pallet automation systems. 

We have worked closely with a variety of clients and industries – including grain & seed, food & dairy, growers, stock-feed, fertiliser, and cement manufacturers. If you are on the lookout for good automated packaging equipment that fulfills your manufacturing needs, feel free to reach out to us and book a free, on-site consultation today. 

One of the most common use cases of automation is within the manufacturing industry, in which equipment, programs, and robotics are utilised specifically to streamline the production process. The ultimate goal of automation is to increase production volume, reduce unit cost, or often both. Most manufacturing companies can find benefits in one or more of these types of automation – fixed, programmable, and flexible. 

Here we discuss the three types of automation and their characteristics to help you gain insights and decide which ones are most suitable for your production processes. 

Fixed Automation 

Also known as ‘hard automation,’ fixed automation describes an automated production facility in which the sequence of processing, or assembly, operations is fixed by the equipment configuration. Although the operations within the sequence tend to be simple, the integration and coordination of many operations into a single piece of equipment renders it to be complex and not easily altered, therefore it is most suitable for product specialisation in which the programs are not intended to be frequently changed. 

For custom-engineered products, the initial investment may be considered to be higher than the other types of automation machinery. However, when utilised for the production of goods with very high demand rates and volumes, the unit cost is attractive compared to alternative methods of production. Examples of fixed automation systems include automated assembly machines, chemical manufacturing processes, material handling conveyor systems, paint and coating automation processes, and machining transfer lines. 

Programmable Automation

Unlike fixed automation, programmable automation describes the process in which products are made in batches, where reprogramming of the production equipment is required to accommodate the new product style of the next batch. This renders it more flexible and facilitating than fixed automation. Due to their lower production rates and higher adaptability, programmable automation machinery is mostly used for low to medium volume production of different products between batches. 

To produce a new set of different products, the system and the physical setup of the machinery must be reprogrammed and changed over, which takes time and results in a period of nonproductivity followed by each production run before a new batch. Numerically controlled machine tools and industrial robots are good examples of programmed automation. 

Flexible Automation

Acting as an extension of programmable automation, flexible automation solves the problem of changeover time and lost production time. This is made possible by the limited number of product varieties when compared to programmable automation. The reprogramming of the equipment in flexible automation is done offline on another computer system, which then will be transmitted to the automated production system. 

Therefore, the time required to input the program of the next product does not interfere with current production. Physical setup changes are made offline and are moved into place simultaneously as the next production line starts. Pallet fixtures play an important role in holding the parts and moving them into position at the workplace. Due to the variety of parts needed to make seamless transitions with no downtime, the product variety produced by flexible automation machinery is limited when compared to programmable automation systems. 

To Conclude

Each type of automation poses its strengths and weaknesses. If your business is looking for specialised production systems that allow for the highest levels of production volume, the fixed automation system is capable to fulfill that requirement. However, if your business prioritises the most product variety and can tolerate production downtime, then a programmable automation system would be best. The middle ground would be the flexible automation system, where there is no downtime, but production volume and product variety sits in the middle of the range. 

At Aurora Process, we can help you identify the potential for improvement, cost reduction, and increased productivity with automated packaging equipment. We are specialists in end-of-line machinery automation & robotics, pallet automation systems, and other packaging automation implementations, who have worked closely with a variety of clients and industries – including grain & seed, food & dairy, growers, stock-feed, fertiliser, and cement manufacturers. Get in touch with us today to book your free on-site consultation. 

More and more companies are utilising the power of automation and robotics to their advantage. The benefits of incorporating machinery automation & robotics into manufacturing are now widely recognised. Since their conception in 1948, palletizers have been imperative to the production chain in factories all over the world. As demand increases, palletizers are increasingly advanced and come in various types and specifications, which breed two main categories – conventional and robotic. 

Before making an informed decision on the type of pallet automation systems suitable for your business, it is crucial to understand the business’ packaging needs. Several useful questions to ask include:

“What is the production volume required both now and in 5 years’ time?” 

“What packaging types and stack pattern requirements do I have now and are these likely to change in the near future?”

“What is my current manual palletizing process costing me per year?”

“What health & safety risks do I have with my current manual palletizing process?”

After fully grasping the production needs of the business, let’s move on to the differences, key features, and benefits of conventional and robotic palletizers. 

Conventional Palletizers 

To provide a complete overview of conventional palletizers, it is essential to dive into the main subcategories: low-level and high-level palletizers.

A low-level palletizer has the product infeed at floor level. Typically a gantry mounted gripper will pick up the bag/case and place it in the required pattern on a stationary pallet. Often a frame is used to help form the pallet stack and keep it uniform. A low-level palletizer has several benefits.

• They are compact and use less floor space than high-level units. This means they can be installed closer to filling equipment and save floor space.
• They are typically the lowest cost palletizer for >20kg payloads
• Maintenance is easier as most of the unit is accessible from floor level.
• Good for low to medium packing speeds

The high-level palletizer is fed via a conveyor into the top of the unit. The bags or cases are placed onto a forming plate that forms each layer and then deposits onto the pallet below. As each layer forms, the pallet is lowered until it has a complete stack and is at floor level ready for moving via conveyor to the wrapping process. This high-level method of palletizing provides the following benefits

• High speed palletizing
• Layer forming and compacting frames, which provide very accurate and tidy stacks
• The ability to stack high pallet loads

Regardless of the two subcategories, conventional palletizers present a number of benefits, which include being more suitable for mid-high speed product processing, easier to troubleshoot without special training, and typically costs slightly less than its counterpart. 

Robotic Palletizers 

The key differentiating feature of this palletizer is the robot arm, which is capable of autonomously performing tasks assigned by a programmable logic controller. The gripper, which is an end-of-arm tool, is a crucial component that is usually customised to handle specific products. 

Depending on the pallet configuration, a robotic palletizer is able to handle one or more units at a time and form multiple layers on a pallet after picking the products off a conveyor. 

Several key advantages offered by robotic palletizers include easier adaptation and increased versatility to accommodate different pallet patterns and product types, less space requirement, the possibility of mixed case palletizing, and the ability to handle multiple different Stock Keeping Units (SKUs) by a single robot. 

To Conclude

Varying on the type of product and process requirement, a specific type of palletizer may be more suitable than the other. Conventional palletizers remain the common choice as a mid-to-high-speed palletizing solution. However, robotic palletizers excel in low-to-mid speed, multi-line, and bag palletizing applications. Their continued technological advancement and falling costs are boosting their popularity and will give them an increasing competitive edge with time. 

At Aurora Process, we are more than able to provide custom automation solutions to suit your needs. Whether it be automatic bag palletizer, bag palletizer, wrapping pallets, or others, we are happy to assist you to find your right industrial packing equipment. Be sure to contact us or book a free on-site consultation today.

Increasingly, manufacturers start to recognise the advantages of automating their packaging processes using a bulk handling system. The reason is simple – when it comes to running a business, efficiency is always the key. The ultimate goal is to spend less and produce more efficiently, hence it is necessary to have the right bulk handling system throughout your warehouse or industrial plant.

Here are 5 ways how a Bulk Handling System can improve your warehouse operations:

Automation Opportunities

Filling a bulk bag typically requires three main steps: rigging/placing the bag, filling the bag, and taking the filled bag away from the machine. Some manufacturers choose to automate their processes step by step, while others may want to improve the whole bagging process altogether. Automating all of these three steps will give you the optimum benefits, helping you to increase your output, and significantly improve your bulk bagging rate. 

An automated bulk bag filling machine can achieve an output of up to 90 bags per hour, while a manual system may only be capable of ten bags under the same timeframe. More bulk bagging systems can be added and sequenced to further increase bag output.   Other automated actions can be added such as de-aeration, cable tying, labeling, and bag conditioning. 

Accurate Data Collection

In order for the warehouse management team to make strategic business decisions, they will need to obtain relevant production-related information. However, manual data collection can have a significant price tag attached to it and will require a lot of time and effort to produce. This is because manually collected data needs to be cross-checked and verified for accuracy and consistency before they can be used for decision making.

On the other hand, an automated bulk handling system will gather the production data automatically, which guarantees much higher accuracy and saves a lot of resources. As such, management will be able to obtain the most recent data before embarking on any important decision.

Enhanced Workplace Safety and Security

A safe workplace is crucial to maintain warehouse operations. In a factory setting, the risk of workplace injury is relatively higher compared to an office setting due to the repetitive and strenuous motions – such as bending, heavy lifting, and reaching. The injuries might also be due to human errors, as sometimes staff needs to work overnight shifts to keep orders flowing out the door on time, which may have huge consequences to your business. In order to minimise these risks, facilities can invest in automation to drastically improve ergonomic conditions, alleviate labor issues and enhance overall productivity. 

A fully automated bulk bagging systems help to improve workplace safety as the machine does all the heavy jobs that often expose staff to injuries, such as filling and palletising. Automated warehouse machines run with utmost efficiency, fulfill orders with complete accuracy, and use significantly less space than a traditional, manual layout. By doing so, warehouses will be able to easily keep up with the flood of orders during peak periods without putting humans at risk.

Increase Production Rate

Warehouses typically use either manual, semi-automatic, or automatic processes and equipment – or a combination of all three – to keep their operations flowing continuously. Investing in the right types of material handling equipment, intelligently organising your warehouse, and implementing an effective management system will help you streamline and enhance your packaging operations. With an effective bulk handling system in place, your business will be able to fulfill orders in the most efficient way possible, thus increasing your production rate and avoid any delays or errors.

However, bulk handling processes are not one-size-fits-all – there are many ways to customize your systems and procedures based on your specific needs. The above-mentioned benefits can only be realised when appropriate bulk bag filling equipment is used, so be sure to choose the right equipment that is best suited for your warehouse.

Conclusion

In conclusion, the answer is yes – a bulk handling system can greatly improve your business. The savings in costs, material handling, warehousing, and transportation can be substantial. If you want to improve your business’ effectiveness and rate of production, it is worth considering an investment in bulk handling systems, such as bulk bagging systems and bulk bag filling machine. 

The more efficient your handling is, the lower your bottom line costs will be. At Aurora Process, we can help you with industrial packaging equipment from start to finish – be it filling, closing, conveying, palletizing, wrapping & control. If you are looking for robotic automation companies to assist with your organisation, be sure to contact us today.

Technology is evolving at the speed of light. Many companies across the globe are exploring robotics, automation, and AI to reimagine the way they do business. This unstoppable progress has brought the Fourth Industrial Revolution to life, which blurs the boundaries between the physical and digital world. It is paving the way for transformative changes for the better, as it has the potential to raise global income levels & improve the quality of life for populations around the world.

But what is The Fourth Industrial Revolution, and what role does Automation and Robotics play in this revolution? Let’s find out.

What Is The Fourth Industrial Revolution?

In January 2019, global leaders gathered for the World Economic Forum. At the top of their agenda was the Fourth Industrial Revolution. Often referred to as the 4IR or Industry 4.0, the term actually comes from Klaus Schwab, founder and executive chairman of the World Economic Forum and author of the book “The Fourth Industrial Revolution”. He used the term for the first time in an article published in 2016.

When referring to the Fourth Industrial Revolution, we refer to how technologies – such as AI, machine learning, robotics, etc – are all interconnected with humans’ physical lives, thus slowly merging our physical and digital world as mentioned above. Similar to the first three industrial revolutions, these changes will speed up production levels – however, this one will occur at a much greater pace and wider scope compared to its predecessor.

What Are The Technologies Driving These Changes?

At the heart of every Industrial Revolution is the technologies driving it. With the Fourth Industrial Revolution, one of the most significant technological developments was Artificial Intelligence. To simplify, AI describes computers that have the ability to “think like humans”, thus they can recognize complex problems, process information, draw conclusions, and make logical recommendations. Artificial Intelligence is said to be one of the key technologies in the sweeping transformation of the economy, society and the labour market. 

Aside from AI, there are other aspects of smart industry that powers 4IR. For instance, machinery automation & robotics are able to perform their task autonomously, optimising factory production and protecting human employees from doing laborious and dangerous tasks. Robotic engineering companies are constantly developing novel technologies to achieve breakthrough levels of speed and productivity and reduce human error.

How a Global Pandemic Accelerates The Revolution

The COVID-19 outbreak has tested the industrial supply chain like never before – in fact, 94% of Fortune 1000 companies are seeing supply chain disruptions during the period. Though unprecedented, the global pandemic is forcing companies to innovate and automate, especially for the labour-intensive manufacturing sector. Industry players who are utilising automated system engineering are able to reduce the number of workers in their manufacturing plants, thus allowing a safe distance between each individual and a smooth transition into the “new-normal”. AI-powered robots are able to assist human workers to perform error-prone and repetitive tasks, which enables companies to maintain the same level and quality of production despite reduced workers.

Digital transformation in the manufacturing process was already going to happen in the near future, regardless of whether there was a pandemic to begin with; but Covid-19 has accelerated its adoption. The disruption has prompted the global industrial supply chain to change in a better way, such as embracing large-scale automation with custom automation solutions. 

The Impact of Robotics and Cognitive Technologies in 4IR

Global pandemic or not, the change in the workforce is inevitable. The demand for physical and manual skills has been declining for the last 15 to 20 years, and this decline will continue with automation machinery. According to McKinsey and Company, the demand for these skills will fall by 11 percent overall in the United States and by 16 percent overall in Europe between 2016 and 2030 alone. The next wave of automation and AI in manufacturing will disrupt production functions in factories through better analytics and increased human-machine collaboration. The so-called “smart factory” will emerge, employing smart robots and automating most of the physical processes of the factory.

Robotic spans a spectrum from the routine process automation of repeatable tasks, to cognitive technologies where machine learning can develop voice and data recognition capabilities. They can learn and improve as they recognize new patterns that get coded into new rules. For all of its potential, it’s still essential to focus efforts where cognitive technologies can work best. The more robotics machines can do for your company, the more time you can utilise your valuable human resources to perform higher value investigative, innovative, and due diligence tasks.

Conclusion

In the end, we as humans are collectively responsible for guiding this Industrial Revolution, as well as the coming ones. The decisions that we make today will affect our lives and shape the future that our children will live in, thus we should grasp this opportunity to collaborate with machinery automation & robotics and shape the Fourth Industrial Revolution to create a future that works for all of us.

There’s no doubt that automated packaging equipment will help to future-proof your company and prepares you to enter the Fourth Industrial Revolution. At Aurora Process, we can help you with industrial packaging equipment from start to finish – be it filling, closing, conveying, palletizing, wrapping & control. If you are looking for robotic automation companies to assist with your organisation, be sure to contact us today.

In today’s economic environment, most companies are aiming to lower their handling costs as much as possible. Automated bulk handling systems make work easier, more timely and effective, and can help to reduce the number of workers needed to perform a task, thus helping manufacturers to lower costs.

In this article, we will discuss the benefits of a well-designed automated bulk handling system.

What is an Automated Bulk Handling System?

Automated bulk handling systems are specialised systems that are built for a specific purpose. It enables manufacturers to manage very high-volume output with minimal manual intervention. These systems are typically designed to manage certain product runs, whether continuous or as batches. The output ranges from individual products to combined products comprising multiple packages. In Australia and New Zealand these systems typically handle product packages up to 1 ton in weight.

The Advantages of an Automated Bulk Handling System

In any form, high-volume handling poses significant challenges for manufacturers. There are three main issues that need to be addressed during the production process.

1. Labour Efficiency and Increased Safety

For instance, the labor required to perform this bulk bagging by hand is ergonomically challenging, while the time and risk quickly adds up to even higher cost. Manual bagging injuries cost companies millions each year in medical costs and lost labour.

A fully automated bulk bagging systems offers the solution to this challenge, helping businesses to deliver maximum efficiencies at all stages of materials handling. The machine does all the heavy jobs that often exposes staff to injuries, such as filling and palletising. By doing so, you are freeing up your staff from tedious and unproductive duties so they can do more valuable work.

2. Reduce Human Errors

Other reasons why companies would benefit from an automated bulk handling system is to reduce errors caused by humans. When doing repetitive tasks, the human brain is likely to switch into “auto-pilot” mode, meaning we are not paying full attention to the tasks in our hand. Not surprisingly, overfilled bags are very common in warehouses that still use manual labor. Contamination and product mishandling are other common issues as humans sometimes make mistakes when storing and handling equipment or materials.

An automated bagging machine lowers the risk of human error, as each bulk bag is weighed, filled, and sealed automatedly by the system. The machines are less likely to mishandle expensive materials and will be able to keep its environment sterile at all times, thus you don’t need to worry about the aforementioned issues. 

3. Time-Saving Benefits

While increased demand for output is always welcomed by any businesses, increasing production to meet the demand is not as easy as it sounds. You can’t just increase your labour by tenfold or expand the areas of production overnight. Moreover, human laborers need to take snack or meal breaks every few hours, as well as many toilet breaks, which could add up to 1-2 hours per day.

On the other hand, a bulk bag filling machine doesn’t need rests in order to function properly, and you can easily program it to fill more orders in less time. Moreover, the machines can improve cycle times, since the material doesn’t need to wait to be transported by a human operator. The time it takes to complete one production cycle becomes shorter and more predictable, which helps to improve cycle time estimates and allows for more accurate due date estimates for customers. 

Therefore, during a period of high demand, you can confidently rely on these machines to finish the job. Be sure to get yours from a trustworthy bag filling machine manufacturer to avoid potential disruptions and ensure a smooth packaging process..

Conclusion

The more efficient your handling is, the lower your bottom line costs will be. Efficient use of labor, reduced excess inventory, better timing and product control, and timely delivery are some of the benefits of having an automated bulk handling system for manufacturers. This is especially helpful with high-volume manufacturing. Moreover, these bag filling machines work diligently and timelessly, which allows you to gain more productivity and value out of every dollar invested. 

Therefore, there’s no doubt that automated bulk handling machines is the right way to go for your company in the long term. At Aurora Process, we can help you with industrial packaging systems from start to finish – be it filling, closing, conveying, palletizing, wrapping. If you are looking for a bulk bagging machine, be sure to contact us today.