Guide to Palletizers for Co-packing and Manufacturing

Let's talk about 'Palletizers,' the humble yet mighty machines at the heart of modern American manufacturing—making our everyday lives so much easier. So, I thought I'd take you on a virtual stroll through the captivating world of Palletizers:

• The Astounding Advancements of Palletizing
  • The Birth of Palletizers
  • Problems with Conventional Palletizing
• The Advent of Robotic Palletizers
  • The Superiority of Robotic Palletizers
  • Benefits of Robotic Palletizers
• The Future of Palletizers in Industry 4.0
  • Do robots really pay for themselves? Investing In Automatic Palletizing Robots
  • Maintenance and Support for Your Palletizing Automation Solutions
  • How to Evaluate Your Facility’s Palletizing Needs and Choose the Right Solution
• Formic's Palletizing Solutions: Zero upfront cost, Zero maintenance costs, 24/7 post-deployment monitoring
  • Embracing Industry 4.0
  • Endless Possibilities in Factory Productivity
• Conclusion: Celebrating the Technological Marvels of Palletizers

The Astounding Advancements of Palletizing

The Birth of Palletizers

You may be wondering, "What's a Palletizer?" In simple terms, a Palletizer is a machine designed for loading and unloading products onto pallets in an organized fashion. The first palletizer was invented over 70 years ago, in 1948 by Lamson Corp. Although it was a mechanical palletizer, it paved the way for the advanced systems we know today.

Problems with Conventional Palletizing

The conventional method of palletizing involved manually stacking products onto pallets, which was a time-consuming and labor-intensive process. According to a report by MHI, the average hourly wage for a material handling worker in the US was $14.72 in 2019. This means that companies were spending a significant amount of money on labor costs for palletizing.

In addition to the high labor costs, conventional palletizing also had a high risk of human error. Workers were prone to making mistakes while stacking products onto pallets, which could lead to damaged products, wasted materials, and costly downtime. According to a report by the National Institute of Standards and Technology, the cost of quality defects in the US manufacturing industry was estimated to be between 2.5% and 5% of total sales revenue.

However, the slow transition away from conventional palletizing in the US has contributed to the rise of foreign manufacturing competition. Many countries, particularly in Asia, have been quick to adopt automated palletizing systems, which has allowed them to produce goods at a lower cost than US manufacturers. According to a report by the Economic Policy Institute, the US lost 2.4 million jobs to China between 2001 and 2013, with a significant number of these jobs being in manufacturing. The adoption of automated palletizing systems is just one factor that has contributed to this trend.

The Advent of Robotic Palletizers

The Superiority of Robotic Palletizers

Robotic palletizers offer several advantages over conventional palletizing methods. One of the most significant advantages is their ability to handle a diverse range of products, including fragile or irregularly shaped items, with ease. This is made possible by the sophisticated arms that come equipped with sensors and cameras to detect and manipulate objects with precision.

Moreover, robotic palletizers eliminate the reliance on inconsistent and often seasonal manual labor, which not only reduces the risk of injury but also allows for a more efficient and streamlined production process. With robotic palletizers, companies can achieve greater speed and throughput, leading to increased productivity and profitability.

According to a report by the Association for Packaging and Processing Technologies, robotic palletizing systems can achieve up to 98% efficiency, compared to 60-70% for manual palletizing. This significant improvement in efficiency can lead to substantial cost savings and margin growth for companies that adopt these systems.

For example, a beverage manufacturing company in the UK saw a 33% increase in efficiency after implementing robotic palletizing systems, resulting in a reduction of labor costs by 50%. In the US, a snack food manufacturer increased their production by 30% and reduced labor costs by 50% after installing a robotic palletizing system.

Furthermore, robotic palletizers can work continuously without the need for breaks, resulting in a 24/7 production cycle. This means that companies can increase their output and meet customer demands more efficiently, leading to improved customer satisfaction and increased sales revenue.

Benefits of Robotic Palletizers

The use of palletizers in modern American manufacturing has indeed made remarkable progress, and robotic palletizers have played a vital role in advancing this technology. These machines offer several benefits that have transformed the manufacturing process, including:

• Increased efficiency: Robotic palletizers can work at high speeds, allowing manufacturers to increase their production output significantly. These machines can also operate continuously without breaks, leading to a more efficient and streamlined production process.
  
  
• Reduced labor costs: Robotic palletizers eliminate the need for manual labor, which not only reduces the risk of injury but also leads to significant cost savings. This means that companies can allocate their labor resources to more critical areas of the production process, resulting in higher efficiency and productivity.
  
  
• Improved workplace safety: Automated palletizing systems offer significant ergonomic advantages, as they address the physical strain and risk of injury associated with manually handling heavy products. The average height of a factory or warehouse worker is much lower than the typical height of a pallet stack (80 inches), which exceeds the recommended ergonomic repetitive work zone of 36 inches. Palletizing tasks often involve lifting and moving bags weighing over 50 pounds, which adds to the physical strain on workers during their 8-hour shifts in environments without air conditioning or heating. By implementing robotic palletizers, companies can alleviate these ergonomic concerns, ensuring a safer and more comfortable workplace for their employees.
  
  
• Enhanced flexibility: Robotic palletizers can handle a diverse range of products, including irregularly shaped or fragile items. This means that companies can use the same machine for different types of products, which increases flexibility and reduces the need for specialized equipment.
  
  
• Greater accuracy and precision: Robotic palletizers are equipped with advanced sensors and cameras that can detect and manipulate products with incredible precision. This means that manufacturers can achieve higher accuracy rates and reduce the risk of product damage, resulting in better quality control and increased customer satisfaction.
  
  

The Future of Palletizers in Industry 4.0

Do robots really pay for themselves? Investing In Automatic Palletizing Robots

You'd be amazed to learn that palletizing robots and cobots can bring about substantial ROI in a relatively short period. For instance, some companies report achieving a complete return on their investment within 18 to 24 months! This impressive ROI is primarily due to the robots' ability to replace the workload of 4-5 human workers, leading to significant labor cost reductions and increased productivity.

For example, a beverage manufacturing company in the UK saw a 33% increase in efficiency after implementing robotic palletizing systems, resulting in a reduction of labor costs by 50%. In the US, a snack food manufacturer increased their production by 30% and reduced labor costs by 50% after installing a robotic palletizing system. As a result, they recouped their initial investment in automation within just 14 months!

With such compelling ROI timelines and real-world examples, it's no wonder that businesses are increasingly enthusiastic about the potential of palletizing automation. 

Maintenance and Support for Your Palletizing Automation Solutions

The fact of the matter is that robotic automation pays for itself, but only when done correctly. There are a number of important precautions that facilities must consider when going the route of system ownership instead of using a company like Formic. The Total Ownership Costs (TCO) of buying and using robots in a factory can be significant. The initial purchase cost is just a small part of the rather large equation here. Other costs to consider include paying for an integrator, installation, maintenance, programming, and training. The cost of maintenance can vary depending on the type of robot and the manufacturer's recommendations for servicing. Additionally, training personnel to operate and maintain the robot can also be a significant cost.

A study by study by the National Institute of Standards and Technology (NIST) found that the TCO for a robotic system can be anywhere from 4 to 20 times the purchase price over its lifetime. For example, if a robot costs $50,000 to purchase, the TCO could be anywhere from $200,000 to $1,000,000 over its lifetime. These costs include installation, programming, training, maintenance, and any necessary upgrades or replacements. However, the same study found that the ROI for robots can be significant, with some companies seeing a payback period of just one to two years.

Therefore,  it's crucial to take into account the advantages of using Formic.co's Robots As A Service (RaaS) approach. Formic enables companies to acquire state-of-the-art palletizing technology with no upfront cost, no maintenance or repair costs, and no integration costs. This allows for more efficient cash flow management and eliminates the need for substantial capital investments.

How to Evaluate Your Facility’s Palletizing Needs and Choose the Right Solution

When evaluating a facility's palletizing needs and choosing the right solution, there are several factors to consider. First, the type of products that need to be palletized should be examined. This includes factors such as size, weight, shape, and fragility. The type of packaging used for the products should also be considered, as this can impact the palletizing process. Additionally, the production volume and speed should be evaluated to determine the appropriate level of automation needed.

Once the facility's palletizing needs have been assessed, the next step is to choose the right solution. There are several options available, including robotic palletizers, cobots, and conventional palletizing equipment. Factors to consider when choosing the right solution include cost, efficiency, flexibility, and scalability. It's important to evaluate the Total Ownership Costs (TCO) of the equipment, including purchase, installation, maintenance, and training, to determine the best long-term solution for the facility's needs.

Sounds a bit daunting right? A report by ABI Research suggests that the RaaS model offers significant advantages over conventional robot purchasing models. RaaS allows companies to avoid the upfront capital expenditure required for robot purchase and installation, while also benefiting from the flexibility of scaling robot usage up or down based on changing production needs. Additionally, the RaaS model transfers the risk of maintenance and repairs to the provider, further reducing the overall cost and complexity of robot ownership.

It's hugely important to choose the right partner when implementing robotic automation in your factory or co-packing facility. Formic is the most customer-centric RaaS provider in this space, and even has a mobile app (pictured below) to show usage and efficiency metrics for all deployed robots.

Formic's Palletizing Solutions: Zero upfront cost, Zero maintenance costs, 24/7 post-deployment monitoring

Formic offers the most comprehensive suite of palletizing solutions that can cater to the specific needs of a wide variety of industries. Their range of palletizing solutions includes palletizing cobots, palletizing robots, conventional palletizers, and industrial palletizers. These solutions are designed to handle a vastly diverse range of products, including bags, boxes, cases, buckets, bottles, cans, and really just about anything. 

Formic's team of integration and deployment experts are the best in the industry. With a deep understanding of automation technology and years of experience, they can quickly learn any production line and identify the most efficient way to implement palletizing automation. From installation to training, they are with you every step of the way to ensure a smooth and successful transition to a more automated and efficient process. The best part? You don't pay unless the system is up and running, making or saving you time and/or money.

In addition, our post-deployment success team is always available to assist you in case anything goes wrong. With just a phone call or email, you can access our team of experts who will diagnose and resolve any issues with your palletizing robot, ensuring that you experience little to no downtime. At Formic, we are committed to providing our clients with exceptional service and support to ensure their success in the world of automation.

Embracing Industry 4.0

With Industry 4.0 on the horizon, I'm positively stoked to witness what lies ahead! Smart factories are amplifying the efficiency of these machines, and the integration of advanced technologies such as artificial intelligence and machine learning is taking palletizing to new heights.

Endless Possibilities in Factory Productivity

The possibilities seem endless for palletizers in the future of manufacturing. As automation continues to evolve, we can expect further enhancements in the capabilities of robotic palletizers, leading to increased productivity, reduced waste, and optimized processes.

Conclusion: Celebrating the Technological Marvels of Palletizers

As the famous American inventor, Thomas Edison, once said, "There's a way to do it better—find it." And undeniably, palletizers have found the 'better' way in the field of manufacturing. Let's celebrate the marvel.