Automated palletising, mixed boxes

Systemex Automation was asked to robotize the palletizing process in order to reduce labour dependency, eliminate physically demanding tasks and successfully complete this first robotization project for a large Canadian retail company.

Palletising process

The process we automate is the palletisation of boxes for storage. These boxes vary in size and arrive on a conveyor in an unpredictable order. There are no restrictions on the order in which they are palletised, and the boxes can be arranged with any other boxes, as the pallet serves only as a means of transport to the warehouse.

Operational Specifications

• Average output: 190 boxes/hour
• Maximum output: 420 boxes/hour
• Product orientation: The labels on the boxes must face the outside of the pallet.

System Overview

Our palletising cell is responsible for preparing pallets, at a rate of between 190 and 420 boxes per hour, up to 152.4 cm (60 inches) high. Cardboard boxes of different sizes arrive on a conveyor from the unloading docks. A robot selects the best boxes according to specific criteria and places them on one of three pallets located at the sides and rear. Once the pallet is complete, it is transported out of the cell, and a new empty pallet takes its place.

Managing Box Dimensions

A 3D vision system located above the roller conveyor measures each box. If the dimensions are correct, the box is registered and continues on its way. If there is an error, or if it does not meet the criteria, the box is rejected to a dedicated ejection system.

Label identification

To position the boxes so that the label is always visible, our cell uses colour sensors to locate the label. The information is recorded for each box.

Robot Palletiser

We use a palletising robot specially designed for this type of application. It has 4 motorised axes and uses a suction tool to handle boxes of different sizes and weights in complete safety.

Features

• Robotic arm
• Advanced safety enabling workflows with human intervention
• Handles boxes weighing up to 50 pounds - Stacks up to 6 boxes per minute (up to 12 with lightweight boxes)
• Stacks pallets up to 60 inches high
• Programmable to handle multiple product references - Capable of handling dividers

Benefits

• Increased productivity and capacity
• Reduced reliance on hard-to-find labour
• Improved consistency, safety and quality of operations
• Reduced Cost of Goods
• Rapid return on investment