According to Technopedia, “Future proof” describes a product, service or technological system that will not need to be significantly updated as technology advances.

Purchasing a Future Proof Palletizer

A palletizer purchased today must be as future-proof as possible because it will likely be in operation until 2034, or perhaps as far into the future as 2044. With a life expectancy of one to two decades, a palletizer built today must be engineered with machine control and layer configuration software, electro-mechanical parts, sensors, robots (for some applications), and other components that will perform efficiently and reliably as the machine ages. The manufacturer of the selected palletizer must also be a long-term partner able to provide after-market service and support capabilities that increase the likelihood of maintaining, and when needed, updating or modifying the palletizer to maximize machine life.

Basic Considerations

There are basic considerations that must be specified when selecting a palletizer. Once the basics are defined, details of the machine that will determine how well suited it will be for operation well into the future can then be considered. Basic considerations for selecting a palletizer are:

1. Production Requirements:

Specifying the products that will be palletized on the machine today, while also accommodating what will need to be palletized far in the future, is an important first step in the process. Such things as the range of:

• Product dimensions

• Product weights

• Package designs

• Materials to be handled

• Pallet heights

that the palletizer will be handling, manipulating, forming into layers, and placing onto a pallet (or no pallet for unitized loads) will need to be specified.

2. Speed of Operation

The range of speeds that the palletizer will need to achieve to meet production requirements will need to be determined. This should take into consideration any surge handling capacity that the palletizer will need to handle.

3. Machine Usage

The number of hours per day that the palletizer will be operating, the range of operating speeds, and weights of items being handled will impact machine life. These requirements will help determine the timing, and type, of recommended routine maintenance needed to keep the machine operating at peak efficiency well into the future.

4. Floor Space and Height Available

The floor space that will be available for palletizer installation, as well as the distance from the plant floor to ceiling, or from plant floor to any obstruction (pipes, ventilation shafts, existing overhead conveyors, etc.) that could impact palletizer installation will need to be determined.

5. Environmental Conditions

The plant environment in the area that the palletizer will be operating, including range of temperature and humidity, and exposure to corrosive substances, must be specified.

A reputable machine manufacturer will be able to analyze this basic information and then make a recommendation regarding the type of palletizer best suited for the application. 

The types of palletizers that will be considered are:

1. Low-level palletizers, which are fed at ground level, with items usually not being lifted until they are placed onto the pallet. Low-level palletizers typically have a smaller footprint, lower throughput rates, are better suited for locations with height limitations and are usually less expensive than high-level palletizers. They are also easier to monitor and maintain, since they operate, and can be accessed, from floor level.

2. High-level palletizers are fed from above, with items typically raised by an infeed conveyor and then pushed, swept or lifted onto the pallet. High-level palletizers have higher throughput and speed capabilities than low-level palletizers, since they can build layers faster and more accurately. They are also better for handling fragile or unstable items. A ladder or stairs will need to be climbed to get to machine level.

3. Robot or Gantry Machine. Gantry style machines were first produced for the packaging industry in the 1950s, while the first robotic palletizer debuted in the early 1960s. Gantry palletizers use a rigid mechanical structure (gantry) which enables manipulation of payloads in 2 to 4 axes. A robotic palletizer will utilize an articulated arm capable of manipulating product in up to 6 axes. A robotic palletizer provides greater flexibility and speed of operation than a gantry system.

Palletizers, both low and high level, can be designed and built as a Gantry style machine or a robotic design.

Changing Packaging Market

Customers’, societies’, and governments’ needs, desires, expectations, and requirements have a large influence on market changes. Several drivers impacting today’s packaging market, and the way products are palletized, are briefly described below.

• Sustainability

The packaging market today is focusing on eco-friendly, sustainability requirements as governments pass more legislation mandating companies reduce the impact their packaging has on the environment. In addition to meeting their statutory requirements, companies are also putting in place strategies intended to make their operations and packaging more sustainable. 2

• Skinny Design Concept

The skinny design concept—making product packaging smaller—is being driven by companies exploring the advantages of reducing the size and weight of product packaging to reduce costs by using less packaging material and lowering shipping costs. 3

• eCommerce

In the United States, e-commerce accounted for over 15.6% of total retail sales in 2023, and forecasts suggest this proportion will continue to climb, reaching approximately 20.6% by 2027

 With this rapid growth, companies must constantly adapt their packaging strategies, design, and practices to keep pace with evolving industry trends.

Today’s drivers of change will be affecting the packaging market for many years to come, while changes that will occur one or two decades from now can only be imagined. That’s why it is important to select a palletizer engineered for the future. Let’s discuss some topics that will have an impact on how future proof your palletizer may be.

Future Proofing

1. Ease of Use

Employee retention is a challenge for most companies. Selecting a palletizer supplier that emphasizes ease of use in their designs and solutions should therefore be a priority as this feature will be applicable during the life of the machine.

The palletizer supplier should have:

• Digital Processes that enable complete Integration between the palletizer and other end-of-line equipment, such as stretch wrapper, pallet stacker, and pallet labeler. Ultimately, the supplier should be capable of producing equipment with common human machine interfaces (HMI), electrical cabinets, and parts for all integrated machines. This commonality will enable plant personnel trained on one machine to apply this knowledge to all integrated equipment so they can quickly, independently, and proactively control machines, restore systems during malfunctions, and communicate using a shared system management language5.

• Comprehensive Training Programs that empowers plant personnel to understand and control the machinery easily and effectively during daily operations.

Prioritizing ease of use ensures smoother operations, reduces risk, and contributes to overall efficiency in the palletizing processes.

2. Machine Safety

The palletizer design should align with customer requirements and global safety standards, such as:

• Category 3 electrical safety measures requires machines be designed to check for faults but also have redundant circuits for all safety functions.

• ISO 13849-1:2023 standard specifies a methodology and provides related requirements, recommendations and guidance for the design and integration of safety-related parts of control systems (SRP/CS) that perform safety functions, including the design of software. 

• OSHA 29 CFR 1910.147 regulation ensures that proper procedures are followed to safely control hazardous energy during machine maintenance, safeguarding workers from potential risks. 

These standards and regulations provide safety requirements for machinery control software and systems including fault detection, emergency stop buttons, safety interlocks, protective barriers, and lockout/tagout procedures. Adhering to these safety specifications minimizes safety risks and prevent hazardous situations while enhancing the overall safety of the palletizer.

3. Industry 4.0

Manufacturers are integrating new technologies, including Internet of Things (IoT), cloud computing and analytics, and Artificial Intelligence (AI) and machine learning into their production facilities and throughout their operations. These Industry 4.0 (fourth industrial revolution) capabilities are achieved by employing smart machines with high levels of automation to create smart factories.

A palletizer that is future proof will be designed with Industry 4.0 capabilities, such as the ability to collect and analyze data which enables better decision making. The palletizer should also combine data from production operations with data from Enterprise Resource Planning (ERP), Warehouse Control System (WCS), and Warehouse Execution System (WES) to create levels of visibility and insight that will increase long-term machine value. Value is also enhanced since data from the palletizer can be used to improve predictive analytics and maintenance to maximize uptime and efficiency while minimize downtime.

4. Packaging Machinery Language (PackML)

PackML provides a standardized way to collect uniform data across machines, lines, shifts, plants and business units. This uniformity is essential to productivity-enhancing initiatives such as Overall Equipment Effectiveness (OEE) analysis and to simplify Manufacturing Execution Systems (MES) functions.

PackML standardizes key data point acquisition across different makes of packaging machinery. It reduces the learning curve for plant personnel by providing a common look and feel. It integrates readily into business systems with Open Platform Communications (OPC), and promotes standardized, flexible data sets. Specifying PackML as a machine requirement is another way of future proofing your palletizer.11

5. Total Productive Maintenance (TPM)

TPM is a comprehensive approach to proactive and preventative equipment maintenance designed to minimize disruptions, defects, and accidents while maximizing equipment efficiency. Partnering with a supplier that incorporates TPM as a pillar of its machine design is another item that should be considered when attempting to select a future proof your palletizer.

The TPM design should include such machine components as:

• Modular belts instead of chains to improve time between needed repair or replacement

• Lexan convers where appropriate so plant personnel can quickly and easily see and assess problems

• Fully accessible parts for easy maintenance and easy operability.

Machines designed using the TPM approach will result in:

• Fewer defects which boosts product quality.

• Reduced downtime which increases productivity and efficiency.

• Increased Equipment Lifespan due to proactive maintenance.

• Quicker reaction to potential machine problems since plant personnel will have the ability to see parts of the machine through the Lexan covers.

CONCLUSION

With a palletizer selected today having the possibility of remaining in operation in as many as 20+ years, it’s imperative that the machine be specified for today’s products, while having the capability and flexibility to safely and efficiently handle the products of tomorrow. This paper has provided an overview of basic parameters that must be specified when attempting to source a palletizer. Once these specifications are determined, the items described in this paper that will improve the likelihood of selecting a palletizer that is future proof must be investigated.

Working with a machine builder that will be a trusted partner during the life of the machine, can produce high quality, long- life expectancy equipment, and has the after-market service and support capabilities to ensure the machine can be properly maintained, repaired, and if needed, modified are essential requirements for successfully selecting a future proof palletizer.