Flexible palletizing of small batches: Automation for high variability
Introduction: The small batch palletizing paradox
Palletizing is a classic, monotonous and physically demanding job, ideal for automation. However, traditional robotic palletizing has always required huge runs of a single product, as any change in box size or palletizing pattern meant a long and costly retooling.
However, today’s manufacturing and logistics companies operate in a high-variability, low-volume mode. The paradox is clear: we need to automate, but we can’t afford the downtime associated with switching from product A to product B. The solution is a flexible palletizing cell, built on collaborative robots and smart software, that reduces changeovers from hours to minutes.
Main part: Pillars of high-variability palletizing
The efficiency of a small batch cell is not based on the speed of palletizing, but on the speed with which it can adapt to a new product. This is achieved by integrating three key technologies.
1. Collaborative robot (Cobot) and safe space
The core of the solution is lightweight and safe collaborative robots (cobots). Thanks to their design, they do not require extensive safety fencing. This saves space and costs and allows the operator easy access to the line when replenishing empty pallets.
Easy programming: The operator can easily teach the cobot a new grip point and end position on the pallet, often by manually guiding the arm. Experienced integrators supply the cell with an intuitive touch interface that does not require knowledge of a programming language to set up a new scheme.
2. Universal gripper and smart sensors
The biggest delay in palletizing is the need to change grippers for different carton sizes. The flexible cell circumvents this problem:
Universal vacuum gripper: The key is a universal vacuum gripper (e.g. from OnRobot), which has an adjustable surface and can grip cartons of different sizes and materials without any mechanical replacement.
Sensors for control: The robot is equipped with sensors that verify that it has actually picked up the boxes and automatically compensate if the box is slightly shifted or differently oriented on the conveyor.
3. Palletizing software and templates
For high variability, software that controls palletizing patterns is critical.
Automatic pattern generation: Advanced palletizing software allows the operator to simply enter box dimensions and pallet dimensions. The system automatically calculates and generates the optimal pallet stacking.
Saving to a library: Once created, the schemes are saved to a software library. Switching to another product is then a matter of a single click on the HMI panel. This allows the operator to start palletizing a new series in less than two minutes.
Economic benefit of rapid re-equipment (ROI)
The high initial investment in flexible palletizing is not returned in labor cost savings, but in minimizing unproductive time - retooling.
Maximize OEE: By reducing changeover time from 30 minutes to 2 minutes, you dramatically increase the overall equipment effectiveness (OEE) of your entire line. Expensive production machines don’t suffer downtime waiting for packaging line service.
Peak-time usage: You can easily move the robotic cell (if it is on an AMR platform) to where it is needed. It is a shared resource for the entire production.
Conclusion: Customized palletizing
Flexible robotic palletizing is a game changer for manufacturers specializing in small and diverse orders. By integrating cobots, universal grippers, and intelligent software, a robot becomes an agile tool that can handle both a ten-pallet batch of one product and ten single-pallet batches of ten different products.
Do you want to eliminate manual effort and expensive downtime when palletizing small batches? Visit svet-robotu.cz and discuss with us a solution that adapts at the speed of a click.