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High Level Palletizers

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High level palletizers can process high-volumes and are much less dependent on carton quality than vacuum robots/cobots. Cartons are supported from the bottom at all times and actively pushed from the side, making this palletizing technique the most robust way of palletizing. Layer palletizers are typically used in end-of-line production environments. In logistics environments they are less common.

A layer palletizer (or high-level palletizer) is a high-speed automated palletizing machine that arranges products into complete layers and then places these layers onto a pallet. Its layer assembly deck consists of conveyors, pushers and clamps that form pallet layer. Once the layer is complete, the assembly deck opens and the cartons drop (a few centimetres) on the pallet below, that is suspended in a lift. During this process step the cartons are being clamped from the side to create stable and consistent pallet loads.

Advantages

  • High throughput: Layer palletizers can handle high-speed operations, processing multiple items simultaneously, often outperforming robotic or manual systems in terms of speed.
  • Consistency: They offer precise, repeatable, and consistent stacking, resulting in stable and uniform pallets, minimizing product damage during transport.
  • Heavy load capacity: Layer palletizers can manage heavier items, making them suitable for industries requiring robust palletizing solutions
  • Resistant to product deviations: Pallet layers use strong pushers and clamps, forcing even deformed products to settle into place on the pallet.

Disadvantages

  • Higher Initial Cost: Layer palletizers typically have a higher upfront investment compared to alternatives like cobots or industrial robot systems.
  • Large Footprint: Traditional layer palletizers require more space, making them less suitable for smaller facilities with limited floor space. Often long inclined belt conveyors are used to transport the cartons to palletizing height of +/- 3m at the cost of precious floorspace.
  • Single SKU: Traditional layer palletizers can only handle one SKU at a time. In case of multi-SKU containers a buffer deck might be required. These buffers have a large footprint and are often difficult to access. They contain numerous control components such as roller drives, sensors, sorters, and merges, which can reduce reliability and increase the need for maintenance.
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