What are palletisers
Palletisers are key machines for automating the END OF LINE process and reducing logistic costs. Palletisers handle incoming packages from one or more production lines in an orderly manner and place them on pallets, optimising pallet stability and load.
Used in various industries, they improve efficiency, reduce operating time and provide greater safety.
This guide will help you understand how they work, the different types available and how to choose the ideal model for your needs. We at Duetti Packaging have a wide experience in this field and you can see the different types of palletisers we produce on our website.
Different kind of palletisers
Automatic palletisers manage the palletising process automatically, i.e. without human intervention. They allow the renewal of pallets and interlayer cards without the need for production downtime. Ideal for large volumes and continuous operations.
They are divided into:
Layer palletisers
These systems prepare and transfer an entire layer of products onto the pallet, ensuring fast, efficient and quality palletisation. The perimeter compacting system allows the outer edges to be aligned during deposit on the pallet. The result is an aesthetically precise pallet. Layer palletisers are ideal for products such as crates, cases, bundles and sacks.
Among Duetti Packaging machines, an example of a layer palletiser is the LAYERPAL10A
Cartesian motion palletizers
This category includes palletisers with cartesian movements (X, Y, Z, W axis). They can handle several lines simultaneously with different products, but the production speed is lower than the layer palletiser.
They are equipped with a gripper configured to product specifications, so unlike the layer palletiser they pick up a one or more products (they do not push a layer) and deposit with a dedicated work cycle.
Depending on the design, they are divided into 2 categories:
- palletiser with upper sliding carriage
- palletiser with side sliding carriage
An example of a cartesian palletiser is our MINIPORTAL model
Robotic palletising cells
Highly customisable solutions using 4- or 6-axis anthropomorphic or circular robots for palletising. These robot palletising cells offer flexibility and space optimisation, adapting to different product types and production layouts. They can also manage several lines simultaneously with different products.
They are equipped with a gripper configured to product specifications, so unlike the layer palletiser they pick up a one or more products (they do not push a layer) and deposit with a dedicated work cycle.
An example of a robotic palletising island is our FLEX ROBOT model
Semi-automatic palletisers
Semi-automatic palletisers are capable of handling the process automatically but require periodic human intervention for certain operations such as pallet handling or interlayer card positioning.
How a palletiser works
A palletiser uses a combination of conveyor belts, gripping or pushing systems and software to organise products on a pallet according to predefined patterns.
The main palletising steps include:
- loading: products are conveyed to the palletiser by conveyor belts
- positioning: the system organises the products in the desired configuration
- stacking: products are placed on the pallet.
Advantages of using a palletiser
- efficiency: reduced operating time and increased productivity
- accuracy: elimination of human error
- safety: reducing the risk of manual handling accidents
- savings: optimisation of operating costs
Areas of application: in which industries palletisers are used?
Palletisers are used in a variety of sectors, including:
- food: food and beverage packaging
- pharmaceutical and cosmetics: handling sensitive products and packaging
- chemical: handling of heavy and potentially hazardous materials
- industrial: handling of bulky and non-standard materials.
Below we give you some basic recommendations when choosing a palletiser. This is information we usually collect in the quotation phase of a project with our customers.
Analysis of business requirements
The main element in choosing a palletiser is to define the production volume, product specifications and available space in a company. Another aspect we define with the customer is the degree of flexibility required for future needs or additions.
To decide which palletising solution is best for your company, it is also necessary to assess the skills of the users and all departments involved (maintenance, production).
Finally, one of the most important pieces of information concerns the working hours (shifts) and the level of service support, by this is intended, response time in case of issues, reliability as well as flexibility of the palletiser supplier.
Compatibility
Compatibility with the packaging materials used or to be used must be assessed.
Production capacity
We always recommend choosing a palletiser that can handle the speed of your production line(s).
Budget and ROI
The investment of a palletiser should be evaluated considering both the initial cost and the long-term benefits, such as operating cost savings and efficiency.
Palletiser maintenance and service
Below is an example of how we at Duetti Packaging handle maintenance and service. Duetti palletisers are designed and built by our technical team according to the strictest quality standards.
Ergonomics, simplicity, safety and efficiency define our daily mission.
The use of premium mechanical and electronic components ensures durability, availability and reliability over time, reducing consumption and maintenance.
Our 24/7 after-sales service composed of programming and mechatronic technicians is available for technical support by telephone or for scheduled or unscheduled on-site interventions. All our machines are equipped with remote assistance, which enables rapid diagnosis and often remote resolution of issues.
A well-stocked automatic spare parts warehouse allows our customers rapid replacements, minimising the impact of any downtime on production.
Duetti provides its customers with an online site for machine life cycle management that allows them to check manuals and exploded drawings, as well as, open service tickets by simply scanning a QR.
Our machines are also equipped with predictive maintenance software that alerts the operator in the event of anomalies or when scheduled maintenance times expire, often interconnected to factory systems in an ‘industry 4.0’ – ‘industry 5.0’ key.
Preventive maintenance
Carrying out regular checks is good practice to ensure optimum performance and reduce downtime.
Innovations and future palletiser trends
Advanced automation and artificial intelligence
At Duetti Packaging, we consider the use of AI-based interfaces to improve palletiser flexibility and efficiency.
A modular and interoperable platform combining AI and IoT Analytics to enable new digital service strategies and provide new instruments for the end user.
Green and sustainable 5.0 solutions
At Duetti Packaging we work to create palletiser solutions designed to reduce energy consumption through IE5 efficiency class motors and intelligent power and energy management provided by converters coupled with super capacitors.
Integration with Industry 4.0
Interconnection to factory IT systems with remote uploading of instructions and/or part programs: machines can be interconnected to factory IT systems. All Duetti Lines are networked. The controllers (PLC or CNC) accept TCP-IP connections (sockets etc.). The customer can interconnect the machines/lines to the factory system with a single Ethernet cable and appropriately chosen software for communication with field equipment (e.g. OPC Standard, OPCUA).
The machine can send to the ERP data referring to alarm history, bar code transit, data strings, production details such as number of packs per minute, etc.; it is also possible to load and modify machine operating parameters remotely. The machine receives consents from upstream and downstream machines so that conveyors and/or downtime can be managed.
Automated integration with the factory’s logistics system or with the supply network and/or other machines in the production cycle: the machine/line can be integrated with the factory’s logistics system.
Possible physical integration in which the machine is served either at input or output by an automated or semi-automated movement/handling system that is in turn integrated with another element of the factory.
At the customer’s request, specific automated tracking systems can be installed on the machines/lines to meet the information integration requirement. DUETTI machines also, or alternatively, have the possibility of exchanging data and information with other machines or information systems via PROFINET or TCP-IP protocol.
Innovations and future trends in palletisers
Advanced automation and artificial intelligence
At Duetti Packaging, we investigate the use of AI-based interfaces to improve palletiser flexibility and efficiency.
A modular and interoperable platform combining AI and IoT Analytics to enable new digital service strategies and provide new tools for the end user.
Green and sustainable 5.0 solutions
At Duetti Packaging, we work to create palletiser models designed to reduce energy consumption through IE5 efficiency class motors and intelligent power and energy management provided by converters combined with super capacitors.
Software for generating palletising solutions
Speedypal is Duetti’s software that eliminates time-consuming programming and automatically generates optimal palletising solutions within seconds.
The main features of the software are:
● 3D graphics
● maximum flexibility for pallet creation (with automatic or manual solutions)
● automatic calculation of the solution
● palletisation simulation
● collision detection
● intelligent label positioning
● the generated solution is sent to the palletiser, which makes it directly