Automated Carton Logistics for Palletizing optimizes the transfer and accumulation of heavy, pressure-sensitive cartoned goods, seamlessly linking packaging lines to palletizers. This system tackles confined, multi-level environments with hygienic, low-abrasion handling, ensuring continuous throughput and preserving product integrity through advanced automation.
The goal was to establish an automated, reliable logistics link for cartoned goods from secondary packaging to palletizing, replacing manual transfers. The system needed to operate within a confined footprint, maintain hygienic conditions with low abrasion, and guarantee a continuous, high-cadence supply to the palletizer. This application handles rectangular cartoned consumer goods, each weighing over 5 kg, with pressure-sensitive surfaces. It is implemented in standard industrial, dry, room-temperature environments, without regular washdown requirements. The integration was a brownfield project within an existing packaging area, featuring confined space and multi-level routing with elevation. Matrix accumulation design, control of contact pressure on cartons, throughput assurance, and gentle low-abrasion spiral elevation were critical processes.
Technical Solution
This carton logistics solution ensures efficient and gentle handling of pressure-sensitive cartoned goods within a confined packaging environment. It seamlessly integrates horizontal transfer, hygienic elevation, and intelligent accumulation to feed palletizers reliably.
The conveyor backbone utilizes VarioFlow Plus VF120 modules for horizontal transfer of cartons from the cartoning area to the palletizer zone. These modules incorporate buffer sections and controlled merges/diverters to manage product flow effectively. For hygienic elevation within the multi-level layout, a VF90 spiral conveyor is employed. This spiral lifts cartons to the required height using low-abrasion, spring-based pressure elements designed to minimize dust generation and contact stress on delicate surfaces. Accumulation and metering are precisely managed through a matrix accumulation design upstream of the palletizer. This system is sized through simulation to ensure optimal performance, with PLC logic and sensors controlling the carton flow to match the palletizer's cycle time. The line control coordinates speed setpoints, accumulation rules, and safety interlocks, ensuring a smooth and safe operation. Rough alignment is sufficient for the palletizer infeed, simplifying integration.
Key Features & Benefits
Transition from manual to automatic: Stable, continuous transfer reduces labor dependency and unplanned stops.
Throughput assurance: Simulation‑driven sizing of accumulation and line speeds ensures a consistent palletizer feed.
Gentle product handling: Controlled contact pressures and low‑abrasion components protect pressure‑sensitive cartons and preserve pack integrity.
Footprint‑efficient elevation: Spiral routing enables multi‑level transfer in confined areas without major civil works.
Reusable architecture: The VF120 + VF90 configuration and buffering logic form a repeatable package for similar secondary‑to‑palletizing applications, reducing future engineering effort and TCO.
Build your Application with Bosch Rexroth Products
The solution shown here is based on a system that integrates various Bosch Rexroth components, including conveyor technologies, automation platform, and structural elements. Please note that you can also purchase these components individually from us to build your specific application. The links to the respective product pages are listed here.
Bosch Rexroth VarioFlow Belt Systems: Enable smooth and reliable transport of workpiece carriers up to 20 kg.
The Bosch Rexroth Aluminum Profiles and EcoSafe Protective Fence Components: Are flexible and ensure compliance and safety.
The ctrlX AUTOMATION Platform from Bosch Rexroth: Manages all processes and tasks and is a flexible gateway to other systems.