Date: 2015-01-16


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  1. the first stage of the investment project:
    - cardboard boxes dimensions: 400x600x170 mm, and 400x600x270 mm;
    - maximum height of loaded pallets: 1800 and 2500 mm;
    - maximum number of pallets: 20 pallets /h;
    - logistical label applicator for pallets wrapped in stretch foil.
  2. installation of three packaging lines with a maximum total capacity of up to 950 cardboard boxes/ hour,
  3. a single palletizing cell with a single industrial robot;

Description of operation:

Cardboard boxes with frozen bread are being taken away from the packing machines of three production lines. Downstream of the packing machine there are conveyors installed which deliver cardboard boxes to the main transport route running to the palletizing line. Cardboard boxes from all the lines are transported along the same route. After the boxes arrive at the palletizing cell, they are identified based on the bar codes. The cardboard boxes identified are directed to the picking and packing stations by angular transfer modules. In addition, a conveyor for redirecting cardboard boxes not identified correctly has been installed on the line.

Before arriving at the picking and packing station, the cardboard boxes are properly rotated by rotating modules installed on the conveyors to ensure the visibility of the label applied on the cardboard boxes on both sides of a full pallet. Then, the cardboard boxes are pushed in pairs onto the picking tables, to form layers consisting of four cardboard boxes. After completing a whole cardboard box layer, a robot equipped with a special compressing gripper picks up a full layer and places it on a pallet. The picking, packing, and palletizing take place at the same time on three independent stations, therefore the robot may simultaneously palletize up to three different products.

After laying the right number of layers on a pallet, the pallet is being moved by roller conveyors to a ring type wrapper. Full, wrapped pallets are labelled with the use of a logistical label applicator. An ALPA-view IT system from Wikpol supervises the labelling of the pallets in cooperation with a PLC controller. The data for the labels are collected from the client's logistic system.

Additional information:

Empty pallets are being released fully automatically without any involvement of the staff. The pallets are being transported from an automatic pallet magazine by means of a chain conveyor. The magazine has a function of releasing individual pallets from a pile delivered in advance. The magazine might be topped up with pallets manually or by means of a forklift truck without the need to pause the palletization process.

The palletization line is secured by means of safety guarding with gates. The palletization and wrapping module cell have been separated with optical safety barriers