Automating drum palletizing for variable container sizes

A manufacturer handling drums needed an end-of-line palletizing system that could support more than one drum size while fitting into an existing operation. The palletizing solution also needed to support a double stacked load configuration without adding unnecessary footprint or complexity.

What the system needed to do

The line produced multiple drum sizes and required a double stacked pallet pattern. The palletizing system also needed to place pallets and slip sheets and verify drum orientation prior to placement due to the way the tool grabs the drum and the need to avoid the latch on the drum rim.Meeting those requirements with conventional equipment would have required multiple pieces of standalone hardware, increasing footprint and integration complexity.

How the palletizing method was selected

We typically approach drum palletizing with conventional palletizers. In this case, the customer had a unique load requirement that called for double stacked loads. That requirement, combined with multiple drum sizes and orientation checks, made a robotic approach the more practical solution.At the required production rate, the robot had enough capacity to manage stacking, pallet placement, and slip sheet placement within a single cell. Designing around that capability allowed us to consolidate functions and keep the layout compact.

System design

The system uses a single robotic palletizing cell with a custom end-of-arm tool and integrated vision.

The cell:

• recognizes drum orientation before picking
• builds a double stacked pallet pattern
• supports multiple drum sizes with quick changeover
• places empty pallets
• places slip sheets between layers

All tooling was designed and built in-house, which kept the system simple and predictable.

Throughput and flexibility

The required production rate allowed all functions to be handled without pushing cycle time limits.

The cell was engineered with additional margin so higher throughput can be supported later without redesign.

Integration into the existing line

The palletizer was designed to fit within the existing line layout and communicate with multiple systems on a new plant layout, receiving product and sending finished pallet loads. Keeping all palletizing functions in one cell reduced footprint and simplified integration.

What this system delivers

• One cell handling multiple palletizing functions
• Vision verification of drum orientation prior to picking
• Consistent double stacked loads across drum sizes
• Compact system footprint
• Fewer components to maintain and support
• Scalable design

Looking to automate drum palletizing?

If manual drum palletizing is slowing things down or creating safety issues, a well-designed automation system can simplify the end of the line without adding complexity. Let’s talk about what that could look like for your operation.