What is palletization? Steps, types and configurations

Palletizing is the process of stacking products on pallets for storage or transportation. It can be done manually, where the workers pile up the produce by hand. While this method offers flexibility, it is laborious, does not optimize throughput, and does not increase the injury rate of the workforce. Alternatively, the palletizing process can be fully automated using robots. Robotic palletizers can have different formats, where on the one hand we find massive inline palletizers that handle high-speed throughput, high volume and on the other hand cobot arms that provide adaptability for handling different sizes and volumes of packaging.

Steps involved in palletizing

Palletizing involves several steps with variable and optional steps depending on specific requirements. Here are the key steps:

1. Step 1: Product preparation

Make sure products are properly packaged and labeled. This step may include quality checks and item sorting.

2. Step 2: Choosing a palette

Choosing the right pallet is key to the stability, safety and efficiency of the palletisation, transport and material handling process. Pallets come in wood, plastic, and metal, each with their own specific advantages: wood for strength and affordability, plastic for durability and moisture resistance, and metal for heavy or high-temperature loads. The choice depends on the type of cargo, weight and handling needs.

3. Step Three: Planning the Layout

Effective pallet layout requires careful planning to optimize space utilization and stability. Cartons are placed with weight distribution and easy access in mind. Shape, size and packaging are taken into account to determine the best pattern while facilitating loading and unloading for greater operational efficiency. This step can be done using software.

4. Step 4: Stacking and securing the load

Make an arrangement plan – stack the products on the pallet according to the plan. To reduce the risk of damage and ensure the safety of handlers during loading and unloading, use stretch film.

5. Step 5: Labeling and documentation (optional)

Labeling products and providing documentation is the final step of palletizing to increase shipping efficiency, ensure regulatory compliance and product traceability. Pallets are marked with information such as contents, weight and handling instructions. Additional information may be provided to indicate origin and lot numbers. Packaging labeling and the delivery of product documentation make logistics and customs clearance more efficient.

6. Step 6: Quality Control (optional)

Perform final inspection to ensure palletized cargo meets all safety and quality standards.

Tips for determining the necessary steps to palletize

Consider factors such as product type, shipping method, and material handling requirements to determine which steps are critical to your palletizing process. Consulting with an expert can help you tailor the process to your specific needs.

Types of automated palletizers

Automated palletizers are increasingly preferred over manual palletizers due to their many advantages. These systems greatly increase productivity by stacking products faster and more efficiently than humans. In addition to reducing labor costs, they help minimize workplace injuries caused by repetitive motion and lifting. Automated palletizers guarantee greater accuracy and uniformity of stacking patterns, improve pallet stability and space efficiency. They can work continuously, which helps to increase production. As technology advances, these systems have become more adaptable, capable of handling a wide variety of product types and sizes. For industries facing labor shortages or increasing production demands, automated palletizers offer a reliable, cost-effective solution that improves operational efficiency and product quality.

There are two main types of automatic palletizers:

• Inline palletizers
  Inline palletizers use fixed machines and conveyor systems to arrange products on pallets. Products move along conveyors and are directed into layers, which are then stacked on pallets. Ideal for high speed and high volume operations. Usually fully automatic, although some models may be semi-automatic.

• Robotic arm Palletizers
  Robotic arm palletizers use an automated arm to pick and place products on pallets. They offer high flexibility and can handle a wide range of product shapes and sizes. Suitable for industries with different product lines or industries requiring frequent changes. It can be fully automated or semi-automated, depending on the setup and requirements.

Configuration of pallets

Pallet configuration refers to the way items are arranged on pallets. It includes data on pallet types and sizes, stacking patterns, layer heights and the number of cases per pallet and row. The main configuration patterns are as follows:

• Column stacking
  Items are stacked directly on top of each other and maintain the same footprint on the pallet. This method maximizes stack strength and stability. It works best for lighter or fragile items and can be prone to tipping over if stacked too high.
• Stacking bricks
  Alternates the orientation of the item in each layer, creating a brick-like structure. This approach provides strong, shift-resistant assemblies. It allows mixing of box sizes, but may reduce the total number of boxes on a pallet.
• Lock patterns
  It uses a rotating floor plan where items are supported by multiple frames below. This method offers excellent stability for high density loads. Provides better bridging strength. It can be more complex to construct. This can cause uneven pressure on individual boxes.

Each pattern has its own advantages and is selected based on specific material handling needs, palletizing process and logistical requirements. Need help choosing a palette pattern? Play with the Robotiq configurator tool.

Conclusion

Streamline your palletizing operations with expert advice. Whether you are new to robotic palletizing or want to optimize, our experts can assess your needs and recommend a solution. From device selection to integration, we help you increase efficiency and reduce costs. Unlock the full potential of your logistics with automated palletizing – contact us today.