Automated mixed case palletizing is an innovative solution that streamlines pallet handling operations. These systems help warehouses increase efficiency, flexibility, and accuracy.
Below, we explore how mixed case palletizing works, the benefits, and factors to consider when implementing these systems in your warehouse.
What is Automated Mixed Case Palletizing?
Mixed case palletizing is the process of arranging products of different sizes, weights, and SKUs onto a single pallet. This method contrasts with traditional palletizing, which stacks the same product types on pallets together. Advanced robotic systems and software coordinate to organize and optimize pallet loads efficiently.
These robotic systems use the following components to automate palletizing:
- Robotic arms: Robotic picking arms have grippers to pick up cases of goods and advanced sensors to carefully stack cases in predetermined patterns onto the pallet.
- Vision systems: Sensors and cameras on the robotic arm gather and provide data about the environment to the robot’s software system, allowing it to make real-time adjustments and identify and handle goods accurately.
- Software: Warehouse automation software processes the data from the vision systems to guide the robotic arm’s movements and determine an optimal stacking plan.
- Automated pallet movers: Pallet-moving autonomous mobile robots (AMRs), like Prime Robotics’ MobilePallet, transport goods to and from the pallet station, or palletizing area.
How Does Mixed Case Palletizing Work?
Automated mixed case palletizing works in several steps:
- Item reception: Items arrive at the palletizing station via pallet-moving AMRs.
- Identification and sorting: Vision systems scan and identify each item and send this information to the software.
- Palletizing plan: The software system develops a stacking strategy that balances the pallet by weight distribution and fragility of items to safely optimize space.
- Execution: Robotic arms execute the stacking plan.
- Quality check and dispatch: A final check is performed for stability and accuracy before wrapping and dispatching the pallet for shipping.
Benefits of Automated Mixed Case Palletizing
Enhanced Efficiency
One of the greatest advantages of automated mixed case palletizing is increased warehouse efficiency and speed. By automating the building of pallets with a variety of products, businesses expedite outbound processes, from retrieving items from storage to packing and shipping.
In some cases, implementing automated mixed case palletizing can cut down packing time by up to 50%, greatly assisting warehouses in meeting market demands.
Increased Flexibility
Handling a diverse range of products is particularly beneficial for warehouses that store a variety of SKUs. Mixed case palletizing systems bring unparalleled flexibility to packing and shipping processes—a great benefit for warehouses responding to frequent market changes and customer demands. These systems may accommodate everything from small trinkets to mid-sized household furniture on the same pallet with ease.
Greater Accuracy and Reduced Error Rates
Accuracy is essential for warehouse operations. Without high accuracy, customer satisfaction and retention will drop. Mixed case palletizing minimizes human error by automating the picking, placing, and stacking of goods onto pallets with intelligent robots and software. This automation keeps orders accurate and consistent, and customers happy. Plus, decreased error rates reduce costs associated with order returns and corrections.
Optimized Space
A warehouse’s use of space greatly impacts overall operational costs. By optimizing space on pallets by arranging and packing them efficiently, more products can be placed on each pallet. Automated mixed case palletizing uses calculated configurations to place and stack items as compactly as possible onto pallets for storage or shipping, reducing the need for additional warehouse space.
Increased Scalability
Mixed case palletizing systems are highly scalable. As business demands increase, these systems can be easily adjusted with minimal disruption to existing operations.
This flexibility lets businesses grow at their own pace—they can add or remove robots as needed, and adjust software to reflect these changes. This scalability is particularly beneficial for businesses with seasonal demand spikes.
Improved Worker Safety
By automating the palletizing process, human workers remain safer. Employees no longer have to engage in the physical strain of lifting, placing, and packing heavy cases onto pallets, which often leads to severe workplace injuries. Decreased risk of injuries not only makes warehouses more attractive to potential workers, but also saves on costs associated with workers’ compensation and health insurance.
Reduced Carbon Footprint
With automated mixed case palletizing, packing and shipping becomes highly efficient. Optimizing space on pallets results in more products being shipped in fewer trips, which reduces carbon emissions associated with transportation.
Plus, the increased accuracy of these systems leads to reduced packaging waste and accidental product damage, which saves businesses costs associated with repacking orders and replacing products.
Happier Customers
The faster and more accurately businesses are able to fulfill orders, the happier customers are. Faster processing times and fewer errors ensure customers receive their orders quickly and as expected, which is essential in building customer loyalty. Plus, businesses save costs associated with returns and replacements, as well as re-shipment.
Factors to Consider
Before implementing an automated mixed case palletizing system, there are a few factors businesses need to consider.
For one, these systems often require a significant investment. Businesses should explore different financing options and ensure they choose the right plan to meet their budgetary requirements. Additionally, businesses must consider how the new system will integrate with existing systems. Warehouses will only experience the maximum benefits of mixed case palletizing if all systems are compatible with one another.
After implementation, staff must be trained on how to manage and maintain the new system. Choosing a robotics partner, like Prime, that works with you to plan and deliver effective training helps ensure employees understand how to operate the system and optimize usage.
It’s important to note that the benefits of implementing automated mixed case palletizing often outweigh the challenges. The return on investment (ROI) of these systems is compelling, as businesses often see a reduction in labor and operating costs quite quickly. In the long term, warehouses that adopt automated mixed case palletizing systems often see increased profits due to higher productivity.
Final Thoughts
With advantages like increased efficiency, enhanced safety, and greater accuracy, automated mixed case palletizing is an excellent solution for warehouses looking to gain a competitive edge. The adoption of these advanced systems is quickly becoming the norm, with early adopters reaping the greatest benefits. By using these automated systems, businesses can streamline their operations, keep workers safer, and improve profitability.
Contact our team to learn how Prime can help you integrate mixed case palletizing into your warehouse.
