For 2 kg lightweight instant noodle cartons, it’s difficult to achieve a capacity of 1,800 cartons/hour using a single-pick solution. This full-layer pick-up palletizer was designed precisely based on the customer’s narrow and long aisle. It can achieve precise, high-speed, and low-energy continuous operation within a footprint of only 2.5 m².
Q1: Why must a dual-station configuration be chosen to meet the 1,800 cartons/hour capacity requirement?
A: The dual-station design eliminates time loss caused by “waiting for pallet change.”
After a traditional single-station palletizer finishes stacking one pallet, it must stop and wait for the pallet to be replaced. In contrast, the dual-station structure allows the equipment to pre-place or retrieve an empty pallet at the other station while performing palletizing actions. This symmetrical lifting system enables seamless picking and placing actions, greatly increasing the action frequency per unit time and ensuring that a high-frequency cycle such as 1,800 cartons/hour does not stop the line.
Q2: How does the full-layer gripping fixture ensure palletizing efficiency and stability?
A: The customized full-layer fixture achieves “one pick, 12 cartons in position.”
For the palletizing specification required by the customer, we use a dedicated full-layer transfer vacuum gripper. It combines mechanical clamping with mechanical bottom-support protection, so even if the carton surfaces are slightly deformed or uneven in height, they can still be gripped firmly. This avoids wasted motion caused by repeated robot picks, ensures the flatness and alignment of full-layer palletizing.
Q3: For 2 kg lightweight cartons, what advantages does a column palletizer have over an articulated robot?
A: Under light-load conditions, the cost-effectiveness and stability of a column palletizer are more prominent.
For 2 kg carton materials, the six-axis flexibility of an articulated robot is actually functionally redundant. The column palletizer uses an independent lifting reducer and servo motor, resulting in a more compact structure, simpler maintenance, and a purchase cost at least 30% lower than that of an articulated robot with the same load capacity. In addition, the vertical layout of the column palletizer makes it more adaptable to working conditions with limited workshop height or narrow space.
Q4: How is carton gripping safety ensured at high capacity?
A: Lightweight modules and precise pressure control greatly reduce the impact on fragile cartons.
This equipment uses an ultra-thin vacuum gripper designed specifically for lightweight handling. Its own weight is extremely light, maximizing the payload used for handling materials rather than for the tool itself. Combined with precise control from the vacuum generator and pressure switch valve, it avoids excessive suction that could damage instant noodle packaging, or insufficient suction that could cause cartons to fall.
Q5: Since layout requirements are strict, what about the equipment’s footprint and maintenance costs?
A: The column design has very low site requirements and is also very energy-friendly.
A single-column structure requires only about 2.5 m² of installation space and can be directly embedded at the end of a conveyor line or between two production lines. Structurally, it adopts a self-balancing counterweight system. During lifting and lowering, the counterweight carriage balances the gravity of the lifting beam, significantly reducing motor drive energy consumption and making the operating cost of high-intensity automated equipment more favorable.
Core Parameter Specification (Based on this recommended series)
| Power supply/Power | AC 380V±/5% three-phase four-wire |
| Pneumatic Requirements | Grippers/Fixtures: 0.6-0.8 MPa, ≥0.3 m³/minTotal air reservoir capacity >600 L |
| Dimensions | Overall height 3m, rotation coverage radius 2.5m, footprint 5×3 m² |
| Cable Length | 3m (from robot body to control cabinet) |
| Palletizing Height Limit | ≤1600mm |
| Applicable Scope | 10-50kg productIncluding: bags, cartons, sheets, blocks, or similar products |
| Palletizing efficiency | 400-500 cycles/hour (theoretical maximum) |
| Power Consumption | Robot body: 6.5 kW |
| Pallet reference | ≤1400×1600mm (including actual stack pattern) |
| Customizable item | Cross arm length, column height, base length, special grippers |
| follow-on upgrade | Vision recognition, pallet conveyor line, ton bag lifting reciprocating mechanism, anti-collapse linkage system |
Choosing SPINROBOTECH means you are purchasing a professional palletizing solution optimized for lightweight full-layer picking. It solves the “handling” problem, builds an efficient “unmanned” logistics node, enabling your production line to maintain sustained competitiveness.