Stretch foil palletizing

Implementation context

Palletizing is placing details on a pallet in a certain way. It is the most robotized process on industrial lines in the world. Due to the monotony, weight of transferred elements and repeatability of works that employees perform, the use of an industrial robot for palletizing is strongly justified. The robot is used for appropriate palletizing of rolls of stretch film according to palletization schemes strictly specified by the customer. The stand consists of two buffers, a set of transporters moving rollers, a magazine of spacers and a robot gripper.

Cooperation and implementation

A factory employs 8 people to work, currently serving two workplaces. Due to the processing time of details at these stations, which is relatively too long to ensure smooth production, they are the bottleneck of the production line. The temporary solution was to create three changes and employ a total of 24 people responsible for servicing this section of production.

Robotic technology will allow the combination of positions and, if one industrial robot is used, reduce the required personnel to just 2 employees for each shift. Considering the number of full-time jobs that have been saved, it is possible to estimate the annual saving of PLN 750,000, assuming that the monthly cost of maintaining one employee was PLN 3,500 gross.

Such high savings result from employment optimization. The cost of designing, adapting and implementing the position did not exceed 125,000 USD, which is why the investment in robotization brings the first profits after just 8 months. In addition to reducing production costs, productivity improved significantly, and the risk of injury to employees resulting from the activities they performed in a given position was reduced.

Benefits

  • Dedicated solution regardless of the requirements of the task
  • Palletizing robots with improved gears are characterized by higher resistance to impacts and other mechanical damage, which translates into minimizing the costs of machine maintenance and service.
  • Detecting the size and type of parts, sorting and detecting height is possible thanks to intelligent vision systems or 3D sensors used during palletizing and allows the use of available space in the most optimal way.
  • Palletizing robots can process over 30 cycles per minute, regardless of the size or weight of the production components they transfer.
  • The 3D sensors used in this solution enable uninterrupted operation of the production line due to the possibility of locating and palletizing elements that are outside of their reference position.
  • Easy to use simulation software allows you to model the arrangement of elements based on virtualization. Once completed, the new configuration can be sent to the selected industrial robot ensuring minimal downtime.
  • The previously defined scheme with which elements are stacked on pallets increases the repeatability and degree of filling of pallets compared to manual palletization
  • The transfer of effort-based operations to mechanical devices reduces the risk of an accident at the workplace and damage to employees’ health, and also enables work in the conditions required for the products, such as the appropriate temperature or humidity