• Boost Wet Wipes Production with a Compact Robotic Palletizer - Boost Wet Wipes Production with a Compact Robotic Palletizer

Boost Wet Wipes Production with a Compact Robotic Palletizer

Conversion and packaging lines are quicker than ever for manufacturers of wet wipes. However, a lot of manufacturers still use human labour to pack large boxes into pallets at the end of the line. The outcome? Wasted floor space, uneven stacking, labour strain, and a throughput limit.

Presenting the little robotic palletizer for wet cleaning. One of the last manual bottlenecks in the manufacture of wet wipes is eliminated by these space-saving robots, which have a small footprint but a significant operational effect. Layouts, pallet patterns, case packer integration, ROI calculations, and things purchasers should look for before investing are all covered in this article.

What Is a Robotic Palletizer?

A robotic palletizer is an automated device designed to arrange goods—typically cases, bundles, or bags—onto pallets in a reliable and repeatable manner. A robotic palletizer utilises a robotic arm equipped with a specialised gripper to remove items from an infeed conveyor and arrange them onto a pallet according to a preprogrammed pattern, thereby eliminating the need for human labour, which can be slow, inconsistent, and physically taxing.

Robotic palletizers provide a small and adaptable substitute for conventional mechanical or layer palletizers, which are big and sometimes complicated. Modern systems are ideal for companies with limited space, such as wet wipes manufacturing facilities, due to their compact design, which often requires only 5 to 8 m² of floor area.

Programmability is the key to a robotic palletizer’s adaptability. With little downtime, operators may rapidly convert between various pallet patterns, case sizes, or even pallet dimensions. For instance, a column stack could be necessary for local retail distribution in one manufacturing run. At the same time, an interconnected brick design would be required for stability during international transport in the future. By simply changing the parameters, the same robotic system can manage both.

Integration is yet another significant benefit. A flawless end-of-line workflow can be ensured by the seamless integration of robotic palletizers with upstream machinery, including case packers, labellers, and wrapping machines. This integration enhances overall equipment effectiveness (OEE), reduces errors, and minimises manual handling tasks.

Robotic palletizers are very valuable for the wet wipes business. Wet wipes cases are heavy yet lightweight, requiring careful handling without compromising stability or speed. That is precisely what robotic arms with customized vacuum or clamp grippers offer: reliable stacking that preserves product quality while satisfying needs for high production speeds.

A robotic palletizer, in summary, is more than just a machine; it is the last component in an automated production chain that guarantees scalability, safety, and efficiency at the end of your line.

Structue of case packer DROID - Boost Wet Wipes Production with a Compact Robotic Palletizer

Why Palletizing Matters in Wet Wipes

Every step of the manufacturing process for wet wipes, including conversion, packaging, and case packing, has undergone substantial automation. Palletizing is one area, however, where many firms still use human labour. The final stage, which involves stacking packed cases onto pallets for shipping or storage, may appear straightforward, but it has a significant impact on productivity, security, and profitability.

First, one of the main concerns is the intensity of work. Wet wipes cases may weigh anything from 8 to 15 kg, and employees may carry hundreds of them in a single shift. In addition to slowing down operations, this repeated strain causes weariness, injuries, and a high personnel turnover rate. Relying on human palletizing is becoming unsustainable due to escalating prices and worldwide manpower constraints.

Second, stability and consistency are essential. During handling or transportation, an improperly packed pallet may collapse, resulting in damaged items, wasted resources, and unhappy customers. From the manufacturing floor to the store shelf, load stability is maintained by the accurate, repeatable patterns of robotic palletizers.

Third, alignment of throughput is crucial. Even though modern case packers can generate 20 to 25 cases per minute, palletizing creates a bottleneck if it cannot keep up. By removing this discrepancy, robots maintain end-of-line speed in harmony with upstream machinery.

Fourth, there is the factor of space efficiency. Wet wipes facilities often have a small floor area, particularly in cleanroom settings that adhere to GMP. A regular layer palletizer takes up 15–20 m², but a small robotic palletizer takes up just 5–8 m², which frees up precious space for manufacturing or storage.

Lastly, smooth flow is essential to overall equipment effectiveness (OEE). Lower productivity and idle time are the results of delays in the palletizing step. By automating this process, ROI is strengthened, uptime is increased, and expenses are decreased.

To put it briefly, palletizing is about enabling efficiency, safety, and dependability across the whole wet wipes supply chain—it’s not just about stacking boxes.

HOW IT WORKS ROBOTIC CASE PACKER FOR WET WIPES PROUCTION DROID - Boost Wet Wipes Production with a Compact Robotic Palletizer

Layouts: Small Footprint, Smarter Flow

Layout design is just as crucial when assessing a robotic palletizer for wet wipes as payload or speed. If the palletizer interferes with the manufacturing floor’s movement, a small footprint is meaningless. The ideal arrangement reduces conveyor runs, increases productivity, and provides space for safe movement of forklifts and operators.

  • Inline Design

The case packer comes right after the inline palletizer. Cases travel a short distance on a conveyor from packing to stacking. For factories with a single manufacturing line, where space efficiency and simplicity are paramount, this arrangement is perfect. With little assistance, the robot at the end of the line drops cases into pallets.

  • Centralized Design

Diverging conveyors or transfer shuttles allow many case packers to feed into a single robotic palletizing cell in a centralized arrangement. This makes it appropriate for factories running two to three wet wipes lines, as it eliminates equipment duplication and minimises capital expenses. Traffic management is crucial to ensure a smooth case flow free of obstructions.

  • Palletizing Cell in Modules

A modular palletizing cell gives producers flexibility as they expand. As production increases, the robot, gripper, and infeed conveyor, mounted on a skid frame, may be moved or rearranged. Businesses that anticipate new product forms, lines, or regular layout modifications may find success with this strategy.

The tiny footprint is the most significant benefit across all configurations. Traditional layer palletizers need 15–20 m², but a robotic palletizer cell usually only needs 5–8 m². This disparity results in valuable space that can be utilised for storage or additional manufacturing equipment.

To put it simply, wet wipes manufacturers benefit from better automation and layouts made possible by small robotic palletizers, which guarantee that every square meter of the plant contributes to throughput and return on investment.

CoRobot Palletizer for Wet Wipes Production DROID 1 1 - Boost Wet Wipes Production with a Compact Robotic Palletizer

Pallet Patterns for Wet Wipes

Although stacking wet wipes containers may seem simple, stability, shipping effectiveness, and store compliance are all directly impacted by the pallet design you choose. The proper design guarantees pallets arrive undamaged while maximizing space in warehouses and shipping containers since wipes cases are substantial while being very lightweight.

Stack of Columns

The most basic approach, known as a column stack, arranges instances in straight vertical rows, right on top of one another. It optimizes pallet height and is quick and straightforward for robotic palletizers to use. However, since the layers don’t interlock, it mostly depends on stretch wrapping for stability.

Brick-like or interlocked pattern

Like a brick wall, each layer is offset or rotated in an interlocking manner. This lowers the chance of pallets collapsing and improves load stability during transportation. For long-distance logistics or export shipments, it’s often the recommended option.

Contradictory Patterns

Some wipe makers balance pallet height and coverage by using mixed or hybrid designs. Alternating brick and column layers, for instance, may increase stability and stacking efficiency. When it comes to fulfilling container loading specifications, where every centimetre matters, this is really helpful.

Standards for Pallets

Pallet dimensions vary depending on the market.

  • In Europe, the Euro pallet (1,200 × 800 mm) is widely used.
  • In Asia and the Americas, the standard pallet (1,200 × 1,000 mm) is extensively used.

At the touch of a screen, operators of a contemporary robotic palletizer may alternate between three to five preprogrammed designs. This adaptability guarantees adherence to client specifications without expensive downtime.

Pallet patterns are ultimately about making sure that everything from your factory floor to the retail shelf is safe, effective, and customer-satisfying, not simply about how cases are stacked.

CoRobot Palletizer for Wet Wipes Production DROID 1 2 - Boost Wet Wipes Production with a Compact Robotic Palletizer

Case Packer Integration

When a robotic palletizer is wholly integrated into the end-of-line system, it produces the highest value. It should seamlessly integrate with equipment above and downstream to provide a continuous and adequate flow, rather than operating independently.

Packing Cases

For cases to arrive in the proper position and spacing, the palletizer and case packer must be in alignment. By ensuring that only quality cases make it to the palletizer, features like rejection lanes, case turners, and accumulation conveyors minimize stoppages and the need for human repairs.

Printers and Labelers

Barcodes, batch codes, or QR codes are guaranteed to face outward on the pallet when integrated with labelers or printers. This helps satisfy retailer and distributor standards, expedites warehouse processing, and enhances traceability.

Machines for Wrapping

The pallet usually goes straight into a stretch wrapper or shrink wrapper once the cases are placed. By connecting these processes, pallets are constructed, stabilized, and prepared for shipping or storage in a single flow that eliminates the need for further forklift movements or human handling.

The Significance of It

The whole end-of-line functions as a single unit when the palletizer, case packer, labeler, and wrapper are in sync. Among the advantages are:

  • Reduced manual touchpoints
  • More dependable and quicker throughput
  • Reduced possibility of product damage or incorrect labeling
  • Increased OEE (overall equipment effectiveness)

Every case that exits the packing machine for wet wipes manufacturers arrives at the warehouse as a sturdy, retail-ready pallet, increasing productivity while lowering labour and error. This is made possible by seamless connection.

CoRobot Palletizer for Wet Wipes Production DROID 2024 1 1 - Boost Wet Wipes Production with a Compact Robotic Palletizer

Buyer Checklist: How to Select the Right Palletizer

Purchasing a robotic palletizer is a long-term choice that impacts customer happiness, labour savings, and efficiency. Wet wipe manufacturers should assess their equipment based on certain key factors to make the best decision.

1. Capacity of Throughput

Verify that the palletizer can handle the 15–25 cases per minute that your case packer can produce. Both single-case and dual-case grippers’ cycle times should be checked.

2. Layout and Footprint

Assess the available floor space and review potential configurations (central, modular, or inline). A small palletizer should not interfere with traffic flow and fit into an area of 5 to 8 m².

3. Technology Gripper

Selecting the appropriate end-of-arm tool (EOAT):

  • Vacuum grippers for cartons that are lightweight.
  • Clamp grippers for boxes that are unsteady or heavy.

If working with bundles or mixed formats, use custom solutions.

4. Flexibility of Pallet Patterns

Make sure there is little downtime when the robot switches between Euro and regular pallets, as well as between column, interlocked, or hybrid patterns.

5. Security and Adherence

Verify that the system complies with international safety standards, such as ISO 13849 and IEC/EN 60204-1, and incorporate collaborative or guarding features as necessary.

6. Readiness for Integration

Verify compatibility with wrapping machines, labelers, conveyors, and case packers. Integration enhances OEE and decreases manual touchpoints.

7. Repair and Replacement Components

Inquire about remote diagnostics, replacement part availability, and local technical help. To prevent expensive downtime, prompt service response is crucial.

8. The capacity to scale

Make development a priority. Select a solution that enables integration with factory MES systems, future updates, or more palletizing cells.

The ideal palletizer isn’t the one with the most specifications; instead, it’s the one that fits your needs in terms of space, product mix, throughput, and long-term growth.

case packer for wet wipes DROID 1 2 - Boost Wet Wipes Production with a Compact Robotic Palletizer

Speed in the manufacturing of wet wipes doesn’t end with packing. Your end-of-line remains as flexible as the rest of your line thanks to a small robotic palletizer, which also reduces labour costs, conserves floor space, increases OEE, and increases return on investment.

Purchasing the appropriate palletizer is a step toward safer, more intelligent, and more profitable production, regardless of the number of wipe lines you operate.

Discover how a little footprint may have a significant influence on your factory by investigating DROID’s wet wipes machine portfolio.

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Using a robotic arm and specialised grippers, a robotic palletizer replaces human labour by autonomously stacking cases or bundles of wet wipes into pallets.

The majority of small robotic palletizers are ideal for workplaces with limited space, as they occupy only 5 to 8 m².

Robotic palletizers may adapt to Euro or standard pallets and alternate between column, interlocking (brick), and hybrid patterns.

Yes. A small palletizer with dual-case grippers can process up to 25 cases per minute, which is comparable to the rates of contemporary case packers.

Low-speed lines (up to around 12 cases per minute) are a good fit for cobots. An industrial robotic palletizer is advised for increased throughput.

It feeds straight into stretch or shrink wrappers, aligns cases, ensures the barcode is oriented, and links via conveyors for a smooth end-of-line flow.

Vacuum or clamp grippers, which are selected according to case weight, carton design, and stacking stability, are used in the majority of systems.

Payback typically lasts 12 to 18 months and is fueled by better OEE, fewer injuries, and labour savings.

Yes, one palletizer may feed two to three wiping lines with a centralized arrangement and divergent conveyors.

Throughput capacity, footprint, flexibility in pallet patterns, safety compliance, integration readiness, service support, and scalability are important considerations.

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