Automated beverage container palletizing system

01

Choose the palletizing principle

KHS explains that in low-level-infeed palletizing a cross conveyor places packs from the conveyor onto a stationary pallet, rising with each layer and returning down for the next, and that this travel limits capacity to about 360 layers per hour unless pallet-change time is shortened — its Innopal PB NF reaches up to 500 layers per hour; with a high pack infeed, around three metres above the floor, the pallet travels down instead, shortening travel and allowing up to 750 layers per hour on its Innopal PB HSS, but requiring two operating levels, a platform with steps and an elevator or spiral conveyor to lift packs. [2]

KHS's Innopal PLR robot palletizer keeps a low infeed and uses separate robots for pack grouping, layer formation and layer pads; it reports up to 625 layers per hour, or a nominal maximum of 135,000 cans per hour depending on diameter, with taller heads for PET and glass bottles handling up to 600 layers per hour, all-sided layer centring and automatic format changeover, and operation by one person with a clear view of the palletizing area. [2]

Editorial calculation: 135,000 cans/h ÷ 625 layers/h = 216 cans per layer, the layer size implied by KHS's two figures; your own rate equals layers per hour × packs per layer × containers per pack. [2]

Give the supplier the pack types and dimensions (with mass and stability), pallet types and patterns, layers per pallet and block height, packs per minute from each line, number of infeed lines, layer-pad and top-frame use, pallet supply and discharge, infeed height, floor space and ceiling height, operator access, safety standard, controls and remote service.

02

Set the rate, pack and pallet limits and robot capability

KHS's data sheet for the Innopal PB-N, a two-column palletizer with an elevated pack infeed for cartons, trays, shrink packs, bags and plastic crates, gives 360 layers per hour with bottom pack infeed and 385 with top pack infeed, a block height including pallet of up to 2,000 mm, pallets 750–1,300 mm across and 750–1,200 mm in the palletizing direction, packs 200–600 mm long, 200–500 mm wide and 100–400 mm high, all-sided centring of each layer before discharge onto the pallet, palletizing with or without pallet liners, and a stainless steel shuttle plate. [1]

ABB's IRB 660 data sheet describes a 4-axis floor-mounted palletizing robot in 180 kg and 250 kg versions, both with 3.15 m reach, 0.1 mm position repeatability, IP67 protection, a 200–600 V 50/60 Hz supply, 2.7 kW power consumption on the ISO cube (3.2 kW for normal movements), a 1,136 × 850 mm base, a weight of 1,650 kg, operation from +5 to +50 °C up to 95% relative humidity and a maximum noise level of 73 dB(A); it rates 2,190 cycles per hour at 60 kg on a standard palletizing cycle of 400 mm up, 2,000 mm across and 400 mm down, and says its reach can serve up to four infeed conveyors, two pallet stacks, one slip-sheet stack and four outfeed lines. [3]

KUKA's technical data for its KR QUANTEC PA palletizing robots lists the KR 140, KR 180 and KR 240 R3200-2 PA models with total loads of 140, 180 and 240 kg, all with a maximum reach of 3,195 mm, floor mounting and IP 65 protection, in standard and food (PA-HO) versions; KUKA says the slim design reaches stack heights of over 2,500 mm, the hollow wrist shaft of 60 mm diameter routes the gripper energy supply, and an Arctic variant works at minus 30 °C without a protective suit. [4]

Editorial calculation: ABB's 3.15 m and KUKA's 3,195 mm reach differ by 45 mm, while the payload steps run 180–250 kg (ABB) and 140–240 kg (KUKA); compare robots on payload at your gripper plus layer mass, not on reach alone. [3] [4]

Editorial note: a robot's cycles per hour are measured on the maker's standard cycle and load; a beverage cell's real rate depends on the gripper (single pack, row or full layer), path lengths, layer pads and pallet changes, so ask for a simulation with your packs and layout.

03

Compare palletizer types

04

From pack infeed to full-pallet discharge

05

Layer rate, pack envelope and the robot's site limits

Convert the throughput row before comparing offers: KHS quotes layers per hour, so multiply by packs per layer in your own patterns to get the packs per hour your line delivers. [1] [2]

06

Send the packs, pallets and line rate together

Paste it into your enquiry below or into an email to a maker, then replace every bracket.

Packs: [type; dimensions; mass; stability]
Pallets: [type; size; patterns; layers; block height; pads]
Rate: [packs/min per line; layers/h]
Principle: [low infeed; high infeed; robot]
Site: [space; ceiling; operator access]
Safety and controls: [standard; guarding; PLC; remote service]

See manufacturer records Send an enquiry through CNFX