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Layer palletizing is a high-speed and cost-effective palletizing solution designed to handle products in complete layers rather than individual items. This technology is especially suitable for high-volume, uniform products such as cartons, bags, shrink-wrapped packages, and trays. IDEA’s layer palletizing systems are engineered to deliver stable, perfectly aligned pallets with consistent height and layer integrity. By palletizing full layers at once, the system achieves higher throughput, reduced mechanical complexity, and lower maintenance requirements compared to robotic solutions in certain applications. Layer palletizing is an ideal choice for manufacturers seeking maximum efficiency, reliability, and predictable performance in continuous production environments.
Layer palletizing is a high-speed and cost-effective palletizing solution designed to handle products in complete layers rather than individual items. This technology is especially suitable for high-volume, uniform products such as cartons, bags, shrink-wrapped packages, and trays. IDEA’s layer palletizing systems are engineered to deliver stable, perfectly aligned pallets with consistent height and layer integrity. By palletizing full layers at once, the system achieves higher throughput, reduced mechanical complexity, and lower maintenance requirements compared to robotic solutions in certain applications. Layer palletizing is an ideal choice for manufacturers seeking maximum efficiency, reliability, and predictable performance in continuous production environments.

Layer palletizing

Layer palletizing is a high-speed and cost-effective palletizing solution designed to handle products in complete layers rather than individual items. This technology is especially suitable for high-volume, uniform products such as cartons, bags, shrink-wrapped packages, and trays.

IDEA’s layer palletizing systems are engineered to deliver stable, perfectly aligned pallets with consistent height and layer integrity. By palletizing full layers at once, the system achieves higher throughput, reduced mechanical complexity, and lower maintenance requirements compared to robotic solutions in certain applications. Layer palletizing is an ideal choice for manufacturers seeking maximum efficiency, reliability, and predictable performance in continuous production environments.

ITEM DETAIL
1. SYSTEM PERFORMANCE

  • Palletizing method: Full-layer palletizing

  • Throughput capacity: Up to 2,000–3,000 products/hour (application dependent)

  • Cycle time per layer: 2 – 6 seconds

  • Operation mode: Continuous, high-duty cycle (24/7)

  • System availability: > 98% (typical industrial operation)
2. PRODUCT HANDLING CAPABILITY

  • Supported products:

    • Cartons and boxes

    • Bags (rice, cement, fertilizer, powdered materials)

    • Shrink-wrapped bundles

    • Trays and rigid packages

  • Product weight per unit: 0.5 – 50 kg

  • Layer weight capacity: Up to 500 – 1,500 kg per layer

  • Product orientation: Fixed orientation per layer

  • Mixed SKU handling: Limited (batch-based)
3. LAYER FORMING & TRANSFER SYSTEM

  • Layer forming methods:

    • Infeed conveyor with layer accumulation

    • Push-type or pick-and-place layer transfer

  • Layer squaring and alignment unit included

  • Optional layer compression for bagged products

  • Layer separator insertion (paper, cardboard, plastic sheets)
4. PALLET SPECIFICATIONS

  • Pallet types: Wooden, plastic, metal

  • Standard pallet sizes:

    • 1,000 × 1,200 mm

    • 1,100 × 1,100 mm

  • Maximum pallet height: Up to 2,200 mm

  • Pallet pattern: Column or block stacking

  • Automatic pallet dispenser: Optional
5. CONTROL SYSTEM & AUTOMATION

  • PLC platform: Siemens / Allen-Bradley / Mitsubishi

  • HMI: Industrial touchscreen with recipe selection

  • Pallet pattern management via HMI

  • Automatic fault detection and alarm handling

  • Production counters and system diagnostics
6. CONVEYOR & PERIPHERAL EQUIPMENT

  • Infeed conveyors: Roller, belt, chain, modular plastic

  • Pallet conveyors: Roller or chain-driven

  • Pallet centering and positioning unit

  • Automatic empty pallet magazine (optional)

  • Integration with stretch wrapper or hooding machine
7. SAFETY & COMPLIANCE

  • Safety standards: CE, ISO 13849

  • Safety fencing with interlocked access doors

  • Emergency stop circuits

  • Light curtains or safety scanners (optional)

  • Safety PLC architecture (optional)
8. UTILITIES & OPERATING CONDITIONS

  • Power supply: 380–415 V / 50–60 Hz / 3-phase

  • Compressed air: 5–7 bar (if pneumatic actuators are used)

  • Operating temperature: 0 – 45 °C

  • Humidity: ≤ 85% RH (non-condensing)

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Cobot palletizing is a flexible and space-saving automation solution designed for low to medium throughput palletizing applications where human-robot collaboration is required. Unlike traditional industrial robots, collaborative robots are equipped with advanced safety features that allow them to operate alongside workers without extensive safety fencing. IDEA’s cobot palletizing systems are ideal for manufacturers seeking a fast return on investment, simple installation, and easy operation. These systems are especially suitable for frequent product changes, limited floor space, and operations transitioning from manual palletizing to automation. With intuitive programming and compact design, cobot palletizing provides a practical entry point into automated palletizing.

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Robotic palletizing is an advanced automation solution designed to stack products onto pallets with high accuracy, consistency, and efficiency. By replacing manual palletizing, robotic systems eliminate common issues such as uneven stacks, misalignment, product damage, and labor dependency. IDEA’s robotic palletizing solutions are engineered to operate reliably in demanding industrial environments, handling a wide variety of products and packaging types while maintaining stable pallet quality and repeatable performance. Our systems are widely applied in food & beverage, building materials, chemicals, FMCG, electronics, pharmaceuticals, and automotive-related industries. With strong expertise in mechanical design, automation control, and system integration, IDEA delivers palletizing solutions that are not only productive but also safe, scalable, and easy to maintain—helping manufacturers reduce operating costs and improve overall logistics efficiency.

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