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Products Description

Industrial high-level palletizer

The industrial high-level palletizer is an automated packaging equipment widely used in many industries such as food, beverage, chemical, and building materials. It is mainly used to neatly and automatically stack various finished materials, such as bagged, boxed, and barreled products, on pallets in a specific arrangement and number of layers, facilitating subsequent transportation, storage, and other processes. In terms of structure, the industrial high-level palletizer is mainly composed of components such as the mechanical main body, gripping device, conveying system,controlled by PLC.  and control system. The mechanical main body usually adopts a frame structure, which has good stability and rigidity and can withstand large loads. The gripping device can be customized according to the type of materials, such as clamping type, vacuum suction cup type, robotic gripper type, etc., to achieve reliable gripping of materials with different shapes and weights. The conveying system is responsible for accurately transporting the materials to the palletizing position. The control system is the "brain" of the high-level palletizer, generally controlled by a PLC (Programmable Logic Controller). Through pre-written programs, it precisely controls the actions of each component to automate the palletizing process. The industrial high-level palletizer has remarkable advantages. In terms of efficiency, it operates at a high speed and can work continuously, with a palletizing capacity of hundreds or even thousands of pieces per hour. Compared with manual palletizing, it can significantly improve production efficiency and meet the needs of large-scale production. In terms of stability and accuracy, relying on its precise mechanical structure and accurate control system, the high-level palletizer can always maintain a stable working state, palletize materials in the set arrangement and number of layers, resulting in neat and standardized stacking, reducing the risk of product damage caused by human operation errors. From a cost perspective, although there is a certain investment required for equipment procurement and installation in the early stage, long-term use can reduce a large amount of labor costs. At the same time, it reduces labor intensity and improves the working environment for workers. In addition, the high-level palletizer has strong flexibility and adaptability. Through simple parameter adjustment and program modification, it can quickly switch between palletizing operations of different specifications and types of products, meeting the diverse production needs of enterprises.The manufacturer of the palletizer is Benson. It saves labor costs and improves production efficiency.

The working process of an industrial palletizerusually includes core steps such as material conveying, positioning and separation, grasping and lifting, translation and palletizing, and pallet replacement. The specific process is as follows:

1. Material Conveying and Front - end Preparation
   Production Line Docking:
   Materials to be palletized (such as packaging bags, cartons, barreled products, etc.) are conveyed from the front - end equipment of the production line (such as conveyors, carton - sealing machines) to the area waiting for palletizing of the palletizer.
   Shaping and Sorting:
   industrial high-level palletizerIf the materials are not arranged neatly (for example, bagged materials may be tilted), they need to be sorted through shaping devices (such as baffles, flattening mechanisms) to ensure stability during grasping.
   In some scenarios, a sorting conveyor is required to adjust the direction of the materials (such as straightening cartons) or sort them according to palletizing requirements (such as staggered arrangement of odd - and even - numbered layers).
2. Material Positioning and Separation
   Triggering of Positioning Sensors:
   When the materials reach the positioning station through the conveyor line, the photoelectric sensor or laser sensor detects the arrival of the materials, triggering the conveyor line to pause or decelerate to ensure the accurate position of the materials.
   Separation and Single - station Processing:
   If the materials are conveyed in groups (such as in multiple rows side by side), they need to be separated one by one through a separation device (such as a push plate, a dial wheel) to avoid interference during grasping.
3. Operation of the Grasping Device (Core Step)
   Selection of Grasping Methods:
   According to the type of materials, the grasping device adopts different forms:
   Clamping - hugging type: industrial high-level palletizerSuitable for regular materials such as bags and cartons, grasped by clamping with two - side clamping plates.
   Vacuum suction cup type: Suitable for cartons and plates with a flat surface, grasped by vacuum suction.
   Mechanical gripper type: Suitable for special - shaped parts or precision products, precisely grasped by bionic mechanical grippers.
   Lifting and Translation:
   After the grasping device clamps/sucks the materials, it is lifted to a set height by a lifting mechanism (such as chains, lead screws, hydraulic cylinders), and then the materials are moved directly above the pallet through a horizontal moving mechanism (such as a rack and pinion, guide rail sliders).
4. Palletizing and Discharging and Layer - type Construction
   Precise Palletizing:
   After reaching above the pallet, the grasping device slowly descends according to the preset layer - type parameters (such as the number of rows, columns, layers, and spacing), stably places the materials at the designated position on the pallet, then releases the grasping device and returns to its original position.
   Logic Control of Layer - type:
   After the single - layer stacking is completed, the system automatically adjusts the grasping path and starts the stacking of the next single - layer (for example, the second layer is arranged staggeredly with the first layer to improve stability).
   Multiple layer - types (such as a "field" - shaped pattern, a "product" - shaped pattern) can be preset through a PLC or industrial computer program to adapt to different product and pallet specifications.
5. Pallet Replacement and Completion of Palletizing
   Full - pallet Detection and Pallet Switching:
   When the current pallet is stacked to the set number of layers, the system triggers a full - pallet signal, and the grasping device pauses operation.
   The full - pallet is moved out by the conveyor line (such as a roller conveyor, an AGV vehicle), and at the same time, the empty - pallet conveyor line sends a new empty pallet to the palletizing station.
   Post - palletizing Processing:
   It saves labor costs and improves production efficiency.The full - pallet can directly enter the winding and packaging process (fixing the goods through a winding machine) or be transferred to the storage area by a forklift.

6. System Monitoring and Exception Handling
   Full - process Automated Control:
   The entire process is uniformly dispatched by a PLC or an industrial robot control system, and the status of each link is monitored in real - time through sensors (such as position sensors, weight sensors).
   Exception Response:
   If there are abnormalities such as material skewing, grasping failure, or pallet deviation, the system automatically alarms and pauses operation, waiting for manual inspection or automatic error - correction (such as retrying grasping, adjusting the position).

Specification

Advantages of industrial high - level palletizers：

I. Ultra-high Efficiency: Breaking through the Bottleneck of Manual Production Capacity1. Continuous High-speed OperationThe high-level palletizer can operate continuously for 24 hours. The palletizing capacity of a single device can reach 500 - 1500 pieces per hour (depending on the material specifications), far exceeding the efficiency of manual palletizing (about 50 - 100 pieces per hour for manual work). For example, in the beverage industry, a single device can easily match the production line's output speed of more than 20 boxes per minute, greatly shortening the order delivery cycle.

II. Precision and Stability: Zero-error Palletizing and Quality Assurance

1. Mechanical Precision and Intelligent ControlIt adopts a servo motor + high-precision guide rail transmission system, and the positioning error can be controlled within **±2mm**, ensuring that each layer of materials is strictly aligned (such as the same row and column spacing in the "field" - shaped layer pattern), avoiding the risks of skew and collapse caused by fatigue in manual palletizing.2. Adaptive Anti-damage DesignIndustrial high - level palletizersThe gripping device is equipped with a pressure sensor (such as soft-start clamping for the clamping type), avoiding extrusion damage to bagged materials;

III. Cost Optimization: Balancing Short-term Investment and Long-term Returns

1. Significant Reduction in Labor CostsA single device can replace 5 - 8 manual palletizers. Calculated at an average annual labor cost of 80,000 yuan per person, it can save 400,000 - 640,000 yuan per year. Especially in regions with labor shortages or high labor costs (such as coastal manufacturing industries), the equipment payback period can be shortened to 1 - 2 years.2. Energy Consumption and Maintenance EconomyModern models generally adopt energy-saving servo motors and an intelligent sleep mode. The standby power consumption is < 1kW, and the operating power consumption is only 60% of that of traditional mechanical palletizers. At the same time, the modular design reduces the maintenance complexity, and the replacement of vulnerable parts (such as gripping rubber pads, sensors) is convenient. The average annual maintenance cost can be controlled within 3 - 5% of the original value of the equipment.

IV. Flexible Adaptability: Fast Switching Ability in Multiple Scenarios1. Compatibility with All Types of MaterialsBagged: flour, chemical fertilizers, feed (clamping type + anti-slip fixture);

1. One-click Switching of Production TasksThrough the Human - Machine Interface (HMI), more than 20 layer pattern programs (such as "pin" - shaped layer, staggered layer, central empty layer) can be preset. When changing products, only the corresponding formula needs to be selected, and the system automatically adjusts the gripping path, height, and arrangement parameters. The switching time is < 5 minutes, meeting the flexible production needs of small batches and multiple varieties.The manufacturer of the palletizer is Benson. It saves labor costs and improves production efficiency.

V. Intelligent Upgrade: Meeting the Requirements of Industry .

01. Full - process Digital MonitoringIt integrates a PLC + Industrial Internet of Things (IIoT) module, which can collect real - time equipment operation data (such as palletizing speed, number of failures, energy consumption curve). It can connect to the factory MES system through the OPC UA protocol, helping to visualize production management.

2. Predictive Maintenance and Remote Diagnosisindustrial high - level palletizersIt is equipped with a vibration sensor + temperature sensor to early warn of mechanical part wear (such as loose chains, overheated bearings), and generates maintenance suggestions combined with cloud algorithms. It supports remote debugging (such as modifying palletizing parameters through VPN), reducing downtime losses

VI. Industry Adaptation Cases1. Food and Beverage Industry: After a dairy factory introduced a high - level palletizer, the palletizing efficiency of milk cartons increased by 300%, the damage rate decreased from 0.5% in manual operation to 0.05%, and at the same time, it met the hygiene requirements of the clean workshop (stainless - steel body + easy - to - clean design).

2. Chemical Industry: In an explosion - proof environment, the explosion - proof high - level palletizer realizes unmanned palletizing of hazardous chemicals (such as bagged caustic soda), avoiding the risk of manual contact and meeting the GB 3836 explosion - proof standard.

Summary: The Leap from "Labor Dependence" to "Intelligent Production"

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Company Profile

Benson Intelligent Equipment (Shandong) Co., Ltd.was founded in 2013, including self-researching and development, design, production and sales. Benson machinery is committed to the design, production and sales of automatic packaging machine, intelligent palletizing machine, wrapping machine etc. Our products are widely used in food, chemical industry, building materials, feed, warehousing and other industries.Benson has 10 senior technical engineers, more than 20 production workers and 10 senior sales,exporting countries including United States,Mexico, Australia, Russia. Saudi Arabia, Singapore, South Africa etc., all over the world, provided professional solution with efficient and intelligent products to each customer, got the high recognization and compliment from every serviced domestic and foreign client. Benson machinery advocates innovation, professional, efficient, pragmatic business philosophy, to achieve mutual benefit and win-win, continue to provide our customers with high-end products and quality service.

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