Rollon Boosts Efficiency in the Palletizing Process with linear axis

Rollon supported the British system integrator AMP Automation in developing a palletizing solution for the packaging line of a major pet food manufacturer in the UK with their linear axes. A specially developed telescopic solution for the Z-axis enables the required dynamics despite severely limited installation space.

The system automates the palletizing of dog food cartons in three different weight classes. After packaging and sealing, the cartons are transported via conveyor systems to a decision point, from which they are automatically fed to one of two palletizing robots. The robots then stack the cartons onto pallets. A two-position concept allows a full pallet to be removed while a second pallet is being loaded at the same time. This prevents production interruptions.

Palletizing under challenging space constraints

Several technical challenges had to be solved for the implementation. The system was required to achieve a cycle time of 7.5 seconds per carton and stack a full pallet in less than six minutes. At the same time, cartons with payloads of up to 20 kilograms had to be moved precisely and reliably. The limited installation space posed a particular difficulty. The system is located in a refrigerated area with insulated ceiling panels that could not be modified. The available headroom was therefore severely restricted. Standard solutions for telescopic Z-axes were out of the question under these conditions.

Customized telescopic solution for limited installation space

Rollon developed a custom solution based on the TLS 230 telescopic system, which is already characterized by a compact, space-saving design. Through design modifications, the unit’s overall height was reduced by an additional 25 to 30 centimeters. This adjustment was crucial for implementing the system within the existing spatial constraints without compromising the required stroke of the Z-axis.

For movements in the X and Y directions, Rollon relied on actuators from its E-Smart product series. The robustly designed units enable high accelerations and were dimensioned to reliably achieve the required cycle times. The integration of the energy supply was also designed to save space. The energy chain was fixed directly on the Z-actuator so that it does not require any additional installation space, even when fully extended.

Flexible solution for future palletizing lines

This offers several advantages for the plant operator. The compact design allows for use even in production environments with limited space. At the same time, the linear technology ensures high process reliability with fast cycle times. Different carton formats can be handled flexibly. Furthermore, the gantry design used can be adapted for other applications. The structure can be used as a standardized solution in future projects, enabling the rapid implementation of new palletizing lines.

Rollon Linear Technology for Dynamic Packaging Automation

The project demonstrates how customized linear technology can help meet complex automation requirements even under challenging conditions. With compact telescopic systems and high-performance actuators, Rollon offers solutions for dynamic and space-saving automation in modern packaging processes.

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