A Guide to High-Level Infeed Palletizers
How They Can Help Increase Production
Topics We’ll cover:
- What a high-level infeed palletizer is
- High-level vs low-level infeed palletizers
- Unitizers vs Palletizers
- How high-infeed palletizers can be utilized in your packaging line
- Pack patterns and why they matter
- What you need to know before buying a high-level infeed palletizer
- Products to use with a high-level infeed palletizer
- Manufacturers we offer
Description of Palletizers and what they are used for:
High-level infeed palletizers can be an essential element of your packaging line. At their core, high-level palletizers receive products at a level above the height of a full pallet and form the pack pattern on a bed. The pallet is raised to bed level and the product is then transferred to the pallet using a sweep arm that will come into place whenever the end of the conveyor has been me. The product layer is then lowered and the next layers of product are continuously stacked on top.. Once the pallet reaches the appropriate height, it is then replaced by another empty pallet to be stacked and the process begins again.
Features:
Some of the key features included in a high-level infeed palletizer are:
- Infeed conveyor - This can either be hand-loaded by workers or it can already have the product ready from downstream. If you are looking to integrate after you purchase equipment, our shop services can discuss your options.
- Sweep arm - The sweep arm will come into place whenever the end of the conveyor has been met and the product has been stacked. It will then be swept over into the collection area, and that's going to be whatever the pallet size is.
Unitizer vs Palletizers:
A decision you will also have to make when deciding how to most efficiently package your equipment is whether to use a palletizer or unitizer. It’s important to consider how your product will be packed and if a pallet is necessary.
- Unitizers do not have a wooden pallet underneath and the product is stacked on top of each other and either strapped or wrapped downstream.
- Palletizers place products onto wooden or plastic pallets and then are wrapped or strapped downstream.
High-Level vs. Low-Level Infeed Palletizers:
You will also want to consider the floorplan and layout of your facility and determine if a high-level or low-level infeed palletizer will work best for your company.
The main difference between a high-level and low-level infeed palletizer is the way the product is placed on the pallet. The high-level infeed palletizer uses an infeed conveyor to raise the product, then a sweeping arm will place the product onto the pallet in its layer. Once in position, the layer is dropped and an additional layer is added until the pallet is complete.
A low-level infeed palletizer works with your floor level conveyors and places the product using not a sweeping arm, but a lift deck that will raise the product to its appropriate layer and places it on the pallet.
Both options are crucial for automation but high-level infeed palletizers offer a higher palletizing speed and their open structure allows for high and proper visibility. They also have a more condensed footprint in your facility, saving you valuable space. However, they can also be a higher cost, so keep that in mind when you are selecting your palletizer. The good news? SIGMA offers financing should you need it.
Types of Packing Patterns:
(Source: https://universalpackaging.co.nz/news/pallet-stacking-patterns/)
One of the most crucial parts of packing a pallet and getting it ready for shipment is stability. The best way to ensure that your product is kept safe during transportation is to find the right packing pattern. Your pattern should stack your product in a secure, yet efficient manner. Packing your product correctly will save you time, space, and money.
A typical pallet is going to be 48”x48” and the high-level infeed palletizer can be programmed to fit your packing pattern. Once the layer is packed, each stack is alternated and be placed on the pallet, effectively building it one layer at a time. This keeps the load stable.
The figure below shows how the packing pattern changes depending on the layer.
Slip Sheet vs Tier Sheet
Additional ways to keep your levels from slipping or falling are going to be deciding if you want to include a slip sheet or tier sheet.
- Slip Sheet - A Slip sheet keeps the pallet itself more stable. These are going to be sheets of paper, a little bit thicker than a standard sheet of paper, that is placed between the lawyers to help keep everything together. Slip sheets can be plastic, heavy laminated Kraft paperboard, or corrugated fiberboard
- Tier Sheet - An tier sheet has the same function but can be made of plastic and is primarily used in the beverage industry. Tier sheets can also be reusable.
Why Use a high-level infeed palletizer:
A high-level infeed palletizer is a fantastic addition to anyone looking to ramp up production and produce high volumes at a greater speed. This is one of the last steps in the packaging process and in doing so, is a dedicated workhorse to your production needs.
The types of production lines that typically use a high-level infeed palletizer are any production line that uses boxes, paper towels, totes bags, etc.
Types of product: cases, bundles, bags, full cans, empty cans, aerosol cans, bins, bottles, boxes, etc. This is a universal machine that can be suited for a wide range of products.
Below are also why using a high-level infeed palletizer is an essential part of your production line:
- Safety - They can also boast light curtains for added safety. They will stop the machine if anything crosses the curtain and prevent employee injury.
- Visibility - There is also the option for an operator platform. This is for operators to watch over the machine.
- Automation - One of the most useful and important parts of the machine is the outfeed pallet conveyor which is used mainly upstream, so when a pallet is complete it can continue on to the rest of the process.
What you need to know before buying:
First and foremost, this machine carries a large footprint at your facility and you will need to ensure you have enough space for the machine. However, once in place, the machines are reliable and require little maintenance.
The machine also should not be used in an area where water, steam, or liquid is used as it can corrode the machine and cause deterioration. This includes areas with high levels of humidity.
To properly calibrate the machines, it’s best to contact the Original Equipment Manufacturer (OEM) and have them send an expert to either install the machine or service them. Modifications can also be challenging so you need to confirm that the machine you find will fit your needs with minimal setup prior to purchasing, It is recommended that the OEM gets involved to see if changes or modifications can be made.
You will also have to consider additional costs for the machine, like any needed parts or tooling, rigging, and freight costs that can be associated with purchasing the equipment. SIGMA can help with any of this through our additional brands: SIGMA Surplus, SIGMA Logistics, SIGMA Integration.
Luckily our team has all the capabilities to assist you with any and all of your needs regarding the purchasing of the machine.
Questions to ask yourself before purchasing:
Being knowledgeable is crucial when making a large purchase, so we wanted to provide you with additional questions to consider and ask before purchasing:
- What is the maximum load height and height of the pallet?
- What is the speed you need to run at?
- What Infeed/outfeed conveyor width and length do you need?
- How big is the overall footprint? Will it fit into your floor plan?
- What pallet size are you currently running and what capacity are you looking to run?
- Do you need additional options including:
- Operator platform
- Outfeed pallet conveyor
- Slip sheet dispenser
- Light Curtains
- Tier sheet dispenser
- What is the product you will be running?
- What is the packing pattern you are looking to utilize and is that compatible?
- Do you need additional upstream or downstream equipment as well, including case packer and tray packer, roller, plastic mat-top, plastic table-top conveyor, stretch wrapper, chain drove live roller, etc.
Palletizer Manufacturers:
We offer a wide range of high-level infeed palletizers made from a vast range of manufacturers, including
- Currie
- Columbia
- Cincinnati Industrial Machinery
Conclusion:
High-level infeed palletizers are a great way to automate and increase the packaging process. Now that you are adequately aware of these machines and what they can do for you, let SIGMA Equipment help you find your next high-level infeed palletizer. Click the button below to get your next project started.
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