Ensuring pallet stability is a vital part of safe and efficient shipping and logistics. Goods that are properly secured are less likely to fall or get damaged, which in turn reduces the likelihood of delays or increased costs.

Therefore, maintaining proper pallet stability is crucial for manufacturers, especially for those involved in high-volume shipping. In this blog, we share best practices for securing a stable load and explain why investing in automation can help deliver consistency every time.

How to ensure pallet stability

A robust stacking strategy is key to ensuring a secure load. Think about:

1. Distributing weight evenly

Place heavier items at the bottom of the pallet to create a strong, stable base and reduce the chances of tipping or imbalance. Each layer of products should have a consistent weight distribution to prevent pressure points that could compromise the pallet’s integrity. Even weight distribution across the surface of the pallet ensures that it remains stable during both storage and transport.

2. Stacking boxes tightly

Gaps between boxes can cause products to shift, impacting stability and increasing the likelihood of product damage. Tight stacking prevents movement within the pallet and keeps the load secure. If gaps are unavoidable, such as between irregular-sized items, use filler materials to fill any empty spaces.

3. Interlocking patterns for strength

Interlocking or bricklaying stacking patterns are highly effective in distributing weight evenly and therefore enhancing pallet stability. By alternating the direction of each layer, you create a more solid structure that resists shifting. This technique ensures the pallets can bear more weight without compromising stability, and it also makes the pallet easier to store and stack efficiently.

Six common load-securing patterns are:

• Block: Boxes are aligned in a simple grid, layer by layer. This works well with uniform box sizes.
• Pinwheel: Layers alternate between horizontal and vertical blocks, “weaving” around a central void. This interlocks each layer, improving stability under sideways force.
• Row: All boxes face the same direction in each layer. While straightforward, it can be less stable if not combined with stretch wrap.
• Brick: Boxes are “staggered” like bricks in a wall. Each box rests partly on two below, so weight is spread more evenly.
• Split row: Each layer is divided into two or more rows. Rows alternate orientation between layers to prevent long, unbroken seams of weakness.
• Hybrid pinwheel: A combination of pinwheel at the core with block layers around it. This provides both interlocking strength and load‐bearing support.

4. Top and centre loading

The load should be properly centred, with products kept within the perimeter of the pallet without overhanging. This prevents instability, especially when pallets are stacked, by ensuring that no single part of the pallet carries too much weight.

5. Wrapping techniques

Once a pallet is stacked, use high-quality stretch film, either hand-held or machine-applied, to wrap it tightly from bottom to top and lock the load in place. Ensuring at least three full revolutions around the base and for uneven loads or mixed sizes, consider a spiral-wrap pattern that overlaps layers for uniform tension. Corner boards or edge protectors can be added before wrapping to reinforce corners and prevent film tearing.

Automated palletising for precision and consistency

Automatic palletisers use advanced robotics to stack products with high precision, eliminating the variability of manual processes and ensuring that every pallet meets optimal load stability standards. Many feature pattern forming software, which automatically calculates the best way to stack products for maximum stability by analysing the size and shape of each item.

All of our automatic palletisers can also be specified with an integrated stretch‐wrapping module. This maintains consistent film tension and overlap on every pallet, guaranteeing a uniform, secure wrap to resist movement and protect products.

Faster and safer operations

Automation not only improves pallet stability but also accelerates the loading process. Automated palletising systems can work continuously, 24/7, without the fatigue that affects manual labour. This not only improves productivity but also reduces the risk of accidents and injuries caused by repetitive manual stacking.
Find out more about our automated palletising systems and how they can improve your operations here.

Spider Robots has been building automatic packing and palletising lines for over 30 years, and are one of Europe’s leading suppliers of palletisers. PALpack is proud to announce that we are the UK’s official agent for Spider Robots.

Spider’s modular palletiser has many impressive features which makes these machines easy to use, very flexible, and compact.

Easy programming

Adding new programs to a Spider palletiser could not be easier as everything is animated on the screen. Simply add your pack size, add your pallet size and the Human Machine Interface (HMI) displays an animated representation of the pack and pallet.

From the HMI, you can move the pack into the position on the pallet, rotate and nudge until it’s in its ideal place. Add another pack and continue until you’ve finished the layer. It’s that easy. You can have up to four variations of layer pattern. Once you have designed your new pallet pattern, simply save it, and recall it whenever you need to in the future.

Quick changeovers

If you need multiple grippers for different pack types, then Spider’s clever quick changeover system makes it simple to do. Each gripper is supplied with an interchangeable connection block. Simply release the four clamps, remove the gripper, place the new gripper into the mating block and snap the four clamps on. All electrical and pneumatic connections are inside the end of the vertical axis, so no need to make any connections. Changeovers are as quick as a couple of minutes.

Modular design for single or multiple production lines

Spider’s system has been designed so that you can have a single production line palletiser, or if you have multiple lines, the frame is extended to accommodate as many lines as you need. If one pick and place head can manage multiple lines, then one head is used – if more are needed for faster production, then more robot gantries can be added.

Flexibility

These palletisers can be fully automated, by adding further modules, such as:

• Pallet de-stackers
• Layer card magazines (including plastic sheets, trays and ridged plastic sheets)
• Pallet conveyors
• Pallet wrappers
• Empty pallet re-stackers

Speeds

These machines can move at a rate of up to 10 cycles per minute. Each cycle can pick multiple packs up, and one of the great innovations from Spider is that, even when multiple packs are lifted, the robot can place each pack into a separate location on the pallet. If the gripper picks four packs up, the robot can move over the pallet into four different positions and place one pack into each. This makes 10 cycles into many more packs per minute. The Spider system also accommodates full layer palletising and de-palletising.

Backup and support

Each machine supplied by Spider has remote access VPN connections. But it doesn’t end there. Each machine is supplied with several cameras which allows access to video from the previous few months, where we can find and identify any issue with the machine or how it has been operated. This is a standard part of Spider Robots offer and makes our backup and support unrivalled. If we need to come to site, we will already know what is needed and can make sure that any spare parts are with our engineers.

Interchangeable parts

Spider has designed their machinery in such a way that all motors are the same size, as well as all sensors, inverters and all other major components. Because of this, you only need a very small spares kit. Our engineers also have a full set of spares in their vehicles, so, when a service or repair is carried out, we can fix anything in one visit.

Products handled

• Boxes
• Trays
• Crates
• Buckets
• Jerry cans
• Drums
• Foil wrapped goods
• Bags
• Sacks
• Doors
• Breakbulk items
• Rolls
• Large panels
• Individual picks to complete layers

To find out more about how we can augment your manufacturing operation with Spider Robots, just get in touch to book your free consultation with PALpack.

The needs of modern manufacturers are evolving: more competition, higher customer expectations and rising costs mean they’re under increasing pressure to improve throughput and enhance efficiency.

For many, this means automating processes – and companies such as Europack are leading the way with advanced technology and innovation. In this blog, we’ll explore Europack’s cutting-edge solutions and how they’re helping companies not only streamline their production lines but also improve sustainability.

Who is Europack?

Europack is a leading name in automation, known for designing and building palletisers and packing equipment to automate end-of-line processes. Started in Italy in 1998, the company now operates in 50 countries and across a wide range of sectors, including food, pharmaceuticals and consumer goods.

Renowned for its research and development and commitment to quality, Europack has established itself as an industry leader by consistently delivering innovative solutions that are both robust and reliable.

Europack’s innovative solutions

Europack’s experts are responsible for two stand-out developments within the industry.

1. The world’s first rotating beam palletiser, a robot palletiser that picks up and stacks goods on a pallet using a pre-determined pattern of movements. The design has been frequently replicated, but no one has managed to achieve exactly the same thing. Featuring one beam with a fixed arm and a product picking head, it has a small footprint but good reach to maximise space on the factory floor.
2. The Winner Green range of palletisers includes the clever Kinetic Energy Recovery System (KERS), cutting-edge technology that captures and reuses energy that would otherwise be wasted during the deceleration or stopping process. Similar to the technology used in hybrid cars, harnessing this reclaimed energy reduces energy consumption by up to 70%.

Tailored systems meet diverse needs

Europack’s automated palletising systems can be customised to handle a wide variety of products from cans and bottles to boxes, bags and bundles. Robot palletisers are equipped with a 360° rotating gripper head that can be changed to suit different products, or fitted with combined heads that can deal with more than one type of package.

Additional features include accessories such as empty pallet store dispensers, interlayer handling devices and automatic pallet picking-up devices, all of which are designed to minimise manual intervention, creating a safer working environment while increasing operational efficiency.

The flexibility of the systems also means they can be integrated with any existing automation. The small footprint makes them suitable for diverse plant layouts and, with the ability to feed multiple lines into the same machine, they’re highly efficient too.

A future-focused approach

Europack’s combination of innovative thinking and sustainability makes it the perfect partner for manufacturers looking to remain competitive in the industry. By embracing automation and green technology, manufacturers can not only boost their efficiency but also meet environmental regulations and reduce their carbon footprint – a key differentiator in today’s market.

To find out how Europack can transform your production line, contact us for more information.

For many manufacturers, time is money. Faster operation and streamlined production result in greater throughput and better manufacturing efficiency, while interruptions cause delays and increase costs.

Therefore, end-of-line bottlenecks, those points in the production process that prevent or slow production, can significantly affect overall performance. Addressing them is key to optimising efficiency, reducing costs and improving product quality.

What is a bottleneck?

A bottleneck occurs when a specific stage or operation in a manufacturing process has less capacity than the stage before or after, creating a point of congestion that slows down or limits overall throughput or output.

Some of the main end-of-line challenges that occur are:

• Downtime
  Including unexpected breakdowns and maintenance issues, downtime is a major cause of bottlenecks in manufacturing operations.
• Product damage and quality control
  Rough handling or inaccuracies during the production process can result in defects or even product recalls, causing significant delays while things are put right.
• Labour shortages
  A shortage of skilled labour, plus the fatigue and inefficiencies that come with manual handling, slows down processes such as picking and packing, causing bottlenecks.
• Packaging and labelling errors
  Poor packaging or labelling mistakes can lead to damaged goods and prevent accurate tracking, leading to delays in reporting and deliveries.

Overcoming the issue of downtime

Downtime happens when production stops or is significantly reduced, and can be planned or unplanned. Planned downtime is a scheduled shutdown for routine maintenance, upgrades or cleaning, whereas unplanned maintenance usually occurs due to an equipment breakdown or failure, or a supply chain issue. Due to its intentional nature, planned downtime can generally be accommodated in production schedules; however, standardised procedures and features such as quick-change tooling help to accelerate the process.

To minimise the risk of unplanned downtime impacting your operations, ensure you have routine inspections and preventative maintenance in place to identify mechanical issues before they escalate. AI-based diagnostics and tracking can also help with this, flagging any problems as they arise.

Reducing product damage and improving quality control

Automated handling systems such as palletisers and sack-filling machines are designed to move goods quickly and accurately, preparing them for delivery or storage.

Palletisers use a robotic arm or other mechanism to sort, transfer and stack boxes, cans, bottles and other packages onto a pallet, either in bulk or one-by-one. Specialist gripping heads ensure goods are handled with care, and additional functions such as banding and stretch wrapping protect goods during transit. Sack-filling machines fill, weigh and seal sacks and bags, ensuring they are filled to the correct capacity every time, minimising waste and improving consistency for the customer.

These systems improve accuracy and attention to detail, ensuring that each product leaving the warehouse meets the required standards. Additionally, vision inspection systems can be incorporated into machinery to catch defects early, further enhancing product quality and reducing errors.

Tackling labour issues

A combination of an ageing workforce and a lack of skills has led to a shortage of labour in the manufacturing sector, but automation can help to overcome this challenge and reduce delays.

By replacing manual tasks with equipment such as palletisers, you can free up human employees to be trained and upskilled to manage the systems, or work in more value-added roles elsewhere in the business. As well as improving efficiency, this also reduces the number of employees working in repetitive and physically demanding roles and thus lessens the risk of manual handling injuries.

There’s also the added advantage that automated systems work around the clock without the need for breaks, holidays or sick leave, enabling manufacturers to deliver consistent output and meet higher production targets.

Preventing packaging errors

Proper packaging is vital to ensure goods are protected during transit and storage. If items are damaged due to poor packaging, this can lead to delays, increased costs and customer dissatisfaction.

In addition to protecting products, packaging and labels communicate important information to customers, including supply chain data, delivery details and tracking codes. Barcodes and batch numbers are essential for tracking and identifying items, especially in the event of a recall, while for food, details such as ingredients and allergens are required by end users and to comply with regulations.

To prevent packaging problems, ensure the type of packaging being used is fit for purpose, is made from durable materials and is properly sealed.

For further advice on avoiding or overcoming end-of-line bottlenecks on your production line, contact us.

For manufacturers, keeping the supply chain running smoothly is critical to maintaining efficiency and profitability. Yet challenges come from all around, causing delays, increasing costs – and emphasising the importance of resilience.

In this blog, we’ll explore more about supply chain resilience, including what it means, why it’s important and how it can be achieved.

What is supply chain resilience?

Supply chain resilience is the ability of a supply chain to anticipate, adapt to and recover from unexpected disruptions, regardless of scale.

From global events to labour shortages and problems with raw materials to equipment breakdown, there’s no telling when or where issues may arise, but overcoming them is essential to ensure production continues.

How to enhance supply chain resilience

To improve supply chain resilience, many manufacturers are turning to automation, using equipment such as palletisers, depalletisers and conveyor systems to streamline material handling and improve overall efficiency.

With the greater speed, precision and reliability that automated systems bring, manufacturers can maintain a more consistent production output, control costs, scale and adapt to changes and thus respond more effectively to unexpected disruptions.

How automation can improve supply chain resilience

This makes automation key to building stronger, more resilient supply chains by:

• Enhancing quality
  Automation improves quality control by ensuring consistency and reducing the likelihood of human error. Machinery such as robotic palletisers can handle a variety of packages with precision, minimising damage and defects and ensuring items are packed with care, to the correct volumes and specifications. On some equipment, AI-powered vision inspection systems can detect inconsistencies and faults, enhancing quality control and preventing faulty products from reaching the customer.
• Strengthening security
  Automated tracking systems, such as RFID and barcode scanning, can be used to accurately record physical deliveries and shipments, reducing the risk of theft or misplacement. In today’s digital world there is also a cybersecurity risk, and measures such as automated threat detection can enhance data security and prevent cyberattacks.
• Improving traceability
  Traceability is crucial for manufacturers to track raw materials, parts and finished products throughout the supply chain, and automation enables real-time tracking to be activated. This can provide precise data on inventory and deliveries, and helps ensure compliance with safety and regulatory standards, as well as improving transparency overall.
• Increasing agility
  A resilient supply chain must be able to adapt quickly to changes in supply and demand, or other disruptions. Automation enables manufacturers to adjust production schedules to scale up or down and optimise material handling with minimal downtime. Equipment can also help to streamline inventory management, allowing manufacturers to stay one step ahead and respond quickly to the changing market.
• Improving sustainability
  A growing priority for manufacturers, automation plays a key role in meeting sustainability commitments. Less product damage and more accurate packaging reduces material waste through inefficiencies, and systems such as Europack’s Kinetic Energy Recovery System (KERS) reduce energy consumption and emissions.
• Reducing costs
  Automation reduces costs through minimising waste, enhancing overall efficiency and reducing labour costs. When repetitive, manual tasks are automated, human operatives can be freed up to add value elsewhere in the business, which also improves productivity.
• Building trust
  All of the above help to generate the reliability, transparency and consistent quality expected between manufacturers, suppliers and customers, which in turn, builds trust. Automation plays a key role in this process by ensuring that every step of the supply chain is handled with precision and consistency.

PALpack were recently contacted by a global organisation via our website who were looking for an end of line palletising solution. Faced with space limitations, multiple product variations and two pallet sizes, various design and logistical challenges arose that made it difficult to find a supplier with the experience and knowledge to offer verifiable solutions to these challenges and design a single, reliable turn-key robot palletising cell.

Other packaging machine specialists had been contacted prior to PALpack, but using our knowledge and experience in bespoke conveying, wrapping and palletisation, we were able to overcome all these challenges, as well as any previously unforeseen by the client, to quickly fulfil the design brief, meet the required output levels and ultimately exceed expectations.

Key challenges

• Available space
• Existing line speeds
• Multiple product variations – two existing lines, each feeding a different pack size, at 350 p/h each (700 p/h total), with two pallets being stacked automatically working out lane priority
• Two pallet sizes requiring automated de-stacking. (1.2m x 1m &1.2m x 0.8m)
• Two different layer card sizes requiring automated positioning
• Efficient use of space to be able to integrate a fully automatic pallet stretch wrapper in addition to the two pallet de-stackers
• Requirement for operator to safely access all four corners of the pallet to manually position corner posts prior to stretch wrapping

Solutions

Available space

With 30 years’ experience in providing reliable end of line automation, we were able to bring to the table:

• Extensive and diverse design capability
• Extensive knowledge of available industry proven solutions
• Determination in producing over 20 different schematics until a working model could be achieved within the space allocated
• Utilisation of chain transfers and/or turntables to reorientate pallets prior to stretch wrapping
• Design and manufacture of compact automated pallet de-stackers

Our experience and knowledge allowed us to design a bespoke, positive mechanical paddle gripper that holds the packs without slippage or damage facilitating:

• Maximised robot speed by handling one pack at a time therefore reducing weight and concentrating grip area
• Ability to cope with slight deviations in pack sizes (if handling two or more packs, the gripper will grip the largest, causing the smallest to slip), this may result in slower speeds to compensate
• Overcoming inertia overrun by single pack handling and minimising pack weight
• Inertia overrun results in stopping the robot due to tripping out the servo drives stopping the cell
• The opportunity to demonstrate that positive single pack handling at high speed can generate a higher output than multiple pack handling
• Versatility in stacking patterns due to single pack handling, and 270-degrees rotation of gripper
• Maximum speeds attained due to single, positive pack gripping
• Central pack stabilising pad ensured pack is placed squarely on the pallet

Multiple pack variations

• Bespoke “user-friendly” pallet stacking design software and user interface
• Ability to store and recall over 100 stacking programs as the files are not stored in the PLC
• Increased PLC speed
• Screen showing machine status and pallet positions

Two pallet sizes

• Compact adjustable pallet de-stacking magazines dispensing each pallet size as required
• Palletiser capable of positioning and stacking both pallet sizes with one robot simultaneously

Two different size layer cards

• Adjustable layer card magazines
• Layer card suction cups automatically retract after positioning

Manual corner post positioning

• Remote panel allows operator to pause the pallet conveyors and safely position 4 x corner posts
• 2 x corner post positioned at a time using a turntable to rotate the pallet by 180 degrees to position 2 x more without fully entering the cell
• Manual light curtain reset to allow conveyors to continue safely after positioning