Product to Pallet Automation

Why Automate?

Should we use automation? How much of the packaging line should we automate?

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Automation affords several major benefits for packaging manufacturers. It reduces operational costs by lowering labor costs and minimizing waste from human interaction, increases throughput and productivity, and creates a safer work environment by replacing repetitive and strenuous manual jobs.

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When it comes to automation, we offer fully integrated lines, from product to pallet. Producers moving from a manual process to automation often are experiencing a mismatch between production speed or volume requirements versus the limitations and costs of manual loading efforts. We can help walk you through the key considerations involving the automation of a packaging process; from primary packaging of the product itself to secondary packaging, palletizing, and tote/basket management.

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We also offer ancillary automation commonly used in the packing process, like checkweigher machines, labeling machines, vision systems and inspection systems are common equipment included in automated packaging lines.

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Feeding

Feeding

A critical first step in any automated packing process is the loading of the product to the primary packaging equipment. The feeding/loading strategy will be decided by three primary attributes: production requirements, state/nature of the product being packaged, and the product presentation for the packaging process.

Automatic Loading

Automatic Loading

Packaging infeeds and outfeeds are designed to manage sorting, orientating, allocating, positioning and inserting products in a quick and safe manner without damaging the product. In the food industry, sanitary/hygienic design is a critical aspect of the loading process.

Secondary Packaging

Secondary Packaging

Secondary packaging protects the product’s primary packaging in-transit and may be the first thing a customer sees as a retail shelf presentation. Case formers, sealers and label applicators offer a faster, more accurate and reliable approach to manual efforts. Secondary packaging automation emphasizes equipment flexibility and strong product control, and provides the ability to allow for quick and easy size changeovers of the packaging machinery.

Palletizing

Palletizing

Palletizing packaging is used to improve the transportation of products in bulk from producers to retail or storage & distribution centers. It provides protection during shipping and storage, allowing more inventory to be moved with easier handling. Shipping and storage environments can be harsh, so tertiary packaging is aimed at optimizing footprint and in-transit protection.

robotic pick and place

Robotics

One of the most noteworthy advancements in automation has involved robotics for pick and place applications. Advancements in robotics are making it easier to replicate the dexterity and vision once only available through human labor. Vision-assisted robots can pick and place products precisely using improved grippers for delicate products.

Centralized Line Control

Centralized Line Control

Our fully automated packaging lines come complete with an Allen Bradley centralized control system. This system manages the interface between each piece of equipment and includes both line and safety functions. The safety system will be made up of emergency stop pushbuttons, safety cables and interlock sensors on all doors. All safety alarms and notifications will be available through the Allen Bradley Panelview HMI.

Tote/Basket Management

Tote/Basket Management

Reusable Plastic Containers (RPCs), also known as “totes” – or in the bakery industry,  “baskets” – are made to accommodate the transfer of a wide range of products and primary packaging types. Reusable plastic totes not only reduce carbon emissions, waste, and natural resource consumption, they offer improved product protection versus cardboard alternatives.

Integrated Lines

Auto Loading of Thermoformer / Tray Sealer

Product loading into a Thermoformer and Tray Sealing machine is from above into the defined cavities. There is a defined loading area, in a thermoforming machine between the forming and sealing devices, and in a tray sealing machine, between the tray denesting and sealing units.

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Crate Ready Systems

Depending on the crate delivery and product transport requirement, there are different concepts defined for crate packing. The requirements are related to the customer needs and to space availability.

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Crate Handling Systems

Management of any plastic crate in the market.

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Complete Automation Solution of Vertical Line

In a vertical wrapping line, the product is received randomly and is introduced in an inclined transport system up to the multihead weigher. This feeding system makes de-dosifying and weighing of the product to be wrapped in the vertical machine. The automation of the line is made with different processing and dosifying units, depending on the application and required production goals.

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Complete Solution of Thermoforming Line

Double wrapping Thermoforming line with plastic crate and carton case loading culminating in only one palletizing system.

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Complete Solution of Flow Pack Line

Automatic wrapping in Flow Pack lines with automatic feeding to cartoneer, crate packing and palletizing.

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Automatic Loading to Flow Pack

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ULMA Robots

The sectors shown represent the areas in which the Automation division is concentrated. These markets are also represented by the Packaging division and as such the experience is complimentary to both the packaging machine and the surrounding automation.

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Automation with Carton Case

Case packing line with ULMA D12H robot with carton case erector and closing machines with hot melt.

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Palletizing Systems

This system is used when product versatility is required and the required production of each product is not high speed. The buffer systems optimizes the palletizing equipment, working with robots or mechanical palletizers. The criteria for selecting an optimum palletizing system depends on the needs of the project for each customer. Two palletizing systems are proposed: palletizing with robot or mechanical palletizing.

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Thermoforming Loading and Plastic Crate Packing Line

Crate packing system integrated in wrapping lines.

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Auto Loading of Thermoformer / Tray Sealer

Product loading into a Thermoformer and Tray Sealing machine is from above into the defined cavities. There is a defined loading area, in a thermoforming machine between the forming and sealing devices, and in a tray sealing machine, between the tray denesting and sealing units.

Request a Quote

Crate Ready Systems

Depending on the crate delivery and product transport requirement, there are different concepts defined for crate packing. The requirements are related to the customer needs and to space availability.

Request a Quote

Crate Handling Systems

Management of any plastic crate in the market.

Request a Quote

Complete Automation Solution of Vertical Line

In a vertical wrapping line, the product is received randomly and is introduced in an inclined transport system up to the multihead weigher. This feeding system makes de-dosifying and weighing of the product to be wrapped in the vertical machine. The automation of the line is made with different processing and dosifying units, depending on the application and required production goals.

Request a Quote

Complete Solution of Thermoforming Line

Double wrapping Thermoforming line with plastic crate and carton case loading culminating in only one palletizing system.

Request a Quote

Complete Solution of Flow Pack Line

Automatic wrapping in Flow Pack lines with automatic feeding to cartoneer, crate packing and palletizing.

Request a Quote

Automatic Loading to Flow Pack

Request a Quote

ULMA Robots

The sectors shown represent the areas in which the Automation division is concentrated. These markets are also represented by the Packaging division and as such the experience is complimentary to both the packaging machine and the surrounding automation.

Request a Quote

Automation with Carton Case

Case packing line with ULMA D12H robot with carton case erector and closing machines with hot melt.

Request a Quote

Palletizing Systems

This system is used when product versatility is required and the required production of each product is not high speed. The buffer systems optimizes the palletizing equipment, working with robots or mechanical palletizers. The criteria for selecting an optimum palletizing system depends on the needs of the project for each customer. Two palletizing systems are proposed: palletizing with robot or mechanical palletizing.

Request a Quote

Thermoforming Loading and Plastic Crate Packing Line

Crate packing system integrated in wrapping lines.

Request a Quote