Plastic Container Blog

I just learned that one of the main benefits of plastic pallets vs. wooden pallets is that plastic pallets are easier to sanitize.  You can read more about this and other benefits by clicking here.

Plastic pallets

Plastic pallets are pallets made of plastic. Plastic pallets are more widely used in Europe than in the rest of the world. Plastic pallets are often chosen over traditional wood pallets because they offer benefits which wood can not. Some benefits over wood include the ability to easily sanitize plastic pallets, resistance to odor, longer service life span, and lighter weight, thus saving transportation and labor costs.

There are 6 main types of plastic processes that are used to make pallets.

High Pressure Injection Molding
Structural Foam Molding
Thermoforming
Compression Molding
Rotational Molding
Profile Extrusion

[edit] History
There is no clear documented time at which plastic pallets first appeared, but the consensus in the pallet industry is that they most likely appeared in the United States after WW 2. Credit is given to ret. B-29 capt Leo Nathans (PDQ PLASTICS INC) for creating plastic pallets for the auto industry to ship car parts when metals were a precious commodity due to war effort.

Modern Material Handling Magazine earliest mention of plastic pallets is in 1964 for a fiberglass reinforced plastic pallet.

Although wooden pallets made from lumber currently have the largest share of the market, plastic pallets will experience
the most increase in demand.  You can read more about this here.

Freedonia Market Research Analyzes Pallets Industry

Cleveland 7/02/2008 02:25 PM GMT (TransWorldNews)

US demand for pallets is forecast to advance more than one percent annually through 2012 to 1.5 billion pallets valued at $16.8 billion.  Pallets made from wood — primarily lumber — will continue to account for the largest share of the US pallet market, while plastic pallets will experience the most rapid gains in demand.  These and other trends, including market share and company profiles, are presented in US Pallets, a new study from The Freedonia Group, Inc., a Cleveland-based industry market research firm.

Wood pallets are forecast to account for almost 80 percent of demand in 2012.  Demand for wood pallets is projected to increase at a rate just below that of the market average, however.  Demand increases will be restrained by the growth of pallet refurbishing services.  These services prolong the lifespans of existing pallets, reducing demand for new pallets.  Environmental concerns about the waste generated by damaged and discarded pallets will also drive continued use of pallet refurbishing, as users seek to reduce the environmental impact of pallet consumption by trying to reuse and refit pallets, rather than disposing of them at the earliest opportunity.

Demand for plastic pallets is projected to advance 2.4 percent per year to over 130 million pallets in 2012.  Plastic pallets are easy to clean, and meet US and international phytosanitary requirements for shipping, making them ideal for product shippers with neither the time nor resources to continually sterilize pallets.  Plastic pallets can last a long time without requiring time-consuming repairs, and can be easily recycled once they have reached the end of their product lifespan.  This durability will restrain demand growth for plastic pallets, as they do not need to be replaced as often as pallets made from such materials as lumber.  Gains in plastic pallet demand will also be tempered by their high cost relative to lumber pallets.

Manufacturers will continue to account for the largest share of demand for new pallets, totaling 78 percent of the market in 2012.  Providers of warehousing and other storage services will post two percent annual gains in pallet demand through 2012.  These companies, which manage pallets and coordinate the shipping and handling of materials from original manufacturer to end user, will need new pallets to expand their operations and more effectively serve existing customers.  These firms serve as third-party storage and shipping agents for manufactured goods; thus they rely on the prompt and efficient delivery of pallets to maximize their profits, and will need large stocks of them to meet demand for their services.

The Freedonia Group is a leading international business research company, founded in 1985, that publishes more than 100 industry research studies annually. This industry analysis provides an unbiased outlook and a reliable assessment of an industry and includes product segmentation and demand forecasts, industry trends, demand history, threats and opportunities, competitive strategies, market share determinations and company profiles.

This article gives you many suggestions on how to protect your pallet racks.  Click here to read the article in entirety.
When racks collide: ways to minimize forklift impacts on pallet rack
July 3rd, 2008by Scott StonePallet racks take a beating over time. They get loaded with exceptionally heavy pallets, by exceptionally powerful lift trucks over and over throughout the course of years. Chances are that if you have pallet rack in your warehouse, it’ll get hit at some point. When it does, inspecting (and generally replacing) it is your best course of action. But what about avoiding that hit, or its dangerous aftermaths in the first place?

Rack is easy to ignore from a safety standpoint. In fact, it’s too easy. Other hazards might stick out like a sore thumb, so there are times plant managers or warehouse supervisors can be less concerned than they should for hundreds of tons of racks and load in a warehouse bustling workers and lift trucks.

Here are some ways to avoid (or minimize) lift truck/rack impacts…

Protect your uprights.This is a no-brainer. You can inexpensively install a variety of rack upright protectors at the base of your posts. You can also put heavy gauge guard rail at the end of aisles. All of this stuff is painted bright yellow. There are metal upright protectors, poly and other types, but the main function is consistent - they deflect impact off of the upright.
Beams should be brightly colored. Ever notice that most manufacturers sell a warm-colored beam (yellow or orange)? They may have green, blue, or gray frames, but the beams are bright for a reason: they’re easy to see for a lift truck driver who’s maneuvering 3,000 pound loaded pallets into rack bays. Avoid dull colored beams, and don’t repaint them a more subdued color to match corporate colors or for aesthetic reasons.
Have a no-repercussions policy for reporting impacts. Guys make mistakes - even good drivers. During a fast paced day, they may smack an upright. You need to know that it happened, so don’t punish them for reporting it. Sometimes, the damage can be slight and the driver will decide it’s in his best interest to let it slide, as if a quick visual inspection can confirm whether or not the accident hasn’t damaged the structural integrity or capacity rating. Let your drivers and warehousemen know up front that you want to know, and that they won’t be reprimanded if they tell you.
Inspect frequently. It’s uncommon for warehouse operators to deploy frequent, proactive in-house rack inspection programs. Make it a part of your routine to inspect frequently, at least monthly. While a quick visual inspection won’t tell you anything other than a rack may have been hit, that’s the start of getting it repaired to safe standards. Less frequently, an independent engineer should inspect your rack. You’ll be money ahead with these simple, inexpensive inspections.When you inspect, look for  (1) Damaged uprights; (2) Damaged or bent beams; (3) Operational and capacity signs; (4) Overloaded beams - are they bent or deflected beneath the load; (5) Is the rack plumb and vertical?; (6) Look for missing beam clips or other connections; (7) Damaged welds; (8)Beams popped out of the uprights; (9) Damaged braces or column protectors.
Post capacities on the rack. Most racks come with stickers and signage that inform you of the capacity. If yours doesn’t, have them made and posted.
Don’t alter your rack or any of its components without professional assistance. Don’t allow cleats or other items to be welded to beams, uprights, bracings, etc, or for its load profile to radically change. If you do make appropriate, engineer-approved changes, change your facility drawings, signage and processes to denote what was done.
Use good pallets, designed for the rack. Your pallet’s design should take into account the nature of the goods being stored and the rack it’s being stored on. Pallets that don’t sit snugly on the beams can cause drops or the loaded items to fall. Pallets that are too small can drop through (and using supports is acceptable, but can reduce your functional capacity). Don’t allow loads to overhang the pallet, and always shrink wrap pallets on high beam levels, since in a collision they can be knocked off more easily.
Load the rack correctly. Too little space above the load can cause damage either in loading or unloading. Leave your lift truck operators plenty of room to maneuver - at least a foot, and preferably more. Make sure pallets are square and balanced on the beams.
Rack is simple, safe and effective storage. To keep it that way, pay attention to the little things, train your people, make them aware that it can be dangerous when abused, hit, loaded incorrectly or overloaded. Training is a key, so spend time to be sure that everyone has their eyes open and reports issues as they see them.

Superior pallet makes remanufactured pallets with recycled lumber and also makes “combo” pallets.  Click here to read more.

Father, Son Growing Superior Pallets in Western New York: Rotochopper Machine Proves Valuable to Grind Residuals, Color Mulch

By Diane M. Calabrese
Date Posted: 7/1/2008

BUFFALO, New York — Second chances often get labeled the stuff of dreams, but hard work and conviction can make them happen. Someone just has to roll up his sleeves and get going.

David Goettel did that when he purchased the assets of a troubled pallet company in western New York and built his own, successful business.

Dave is the president and CEO of Superior Pallets Inc., which dates to 2000. His son, Jeff, vice president, joined the company full-time in 2001.

The name Superior Pallets was selected to put the focus on the company’s philosophy of melding superior products to superior service, said Jeff. Superior processed 800,000 pallets in 2007. Most were repaired or dismantled to reclaim used lumber for repair stock or to make remanufactured or combination pallets. Scrap pallets were processed by grinding.

Superior Pallets repairs pallets, makes remanufactured pallets with recycled lumber and also makes combination or ‘combo’ pallets with some recycled lumber and some new lumber. For new lumber the company buys pre-cut stock. Although pallet repair and recycling is the company’s dominant focus, about 10% of the company’s pallet production is new pallets. The company’s operations employ about 40 workers.

Superior Pallets serves various manufacturing businesses in western New York and northwest Pennsylvania. The company is located in Buffalo, a city of about 300,000 people. The business occupies 14 acres near Interstate 90. Drivers for the company log an average of 325 miles and five stops each day.

The company’s operations, including dismantling pallets for recycled lumber and retrieving surplus pallets for customers, generate a considerable volume of scrap wood material and pallets.  In the spring and summer, the company grinds the material to produce mulch; starting in mid-September, the grindings are sold to markets for boiler fuel.

“In 2007, we ground 7,000 tons of wood waste,” said Jeff. The machine that got the job done is a Rotochopper MC-266 mobile wood grinder. Superior Pallets purchased the Rotochopper in the fall of 2006 after a fire destroyed its existing grinder. Rotochopper is headquartered in St. Martin, Minn.

“We were really interested in the Rotochopper because it could color and grind,” said Jeffrey. Rotochopper machines grind wood material and color the resulting mulch in one pass through the machine.

About half of the mulch made by Superior Pallets is colored — red, black or brown. All mulch is sold bulk wholesale to local governments, landscapers and other markets. The company also produces a wood mulch that meets the American Society for Testing and Materials standard for playground surface material.

Superior Pallets buys Mulch Magic colorants from Colorbiotics. The dyes in Colorbiotics products are derived from plants, so the resulting colored mulch is environmentally friendly. Colorbiotics is an independent business unit of Becker Underwood.

The MC-266 Rotochopper is an “excellent” machine, said Jeff. The company normally uses it to produce about 30 tons of mulch per day. It has the capacity to do much more, but for now, Superior matches grinding operations with the volume of scrap wood it produces. “We’re meeting our needs,” said Jeff. Expanding may be in the future, but for now Jeff wants to use the machine only to handle in-house wood waste.

Because the Rotochopper replaced another grinder that was quite old, Jeff expected good performance because the machine was new. He got it and more, starting with dependability.

“The reliability is great,” said Jeff. “The run time has just been amazing.” He has been especially pleased with the Rotochopper’s ability to produce colored mulch in one pass through the machine. Changing screens is quick and easy, too, he said. “One guy can change the screens in about 20 minutes,” said Jeff.

All that efficiency, and the Rotochopper stands up to heavy-duty grinding and steady hours. “We’ve had very few problems with the machine,” said Jeff. “Rotochopper has a service representative in Pennsylvania who stops in periodically” just to check on the machine, said Jeff. That service means a great deal because it demonstrates commitment to the customer, he added.

Commitment to customer is a business approach with which Jeff and his father can identify. “We’re always looking to improve our business,” said Jeffrey, including improving processes and efficiency. Commitment to customers includes listening to them and interacting with them, which is enhanced with Customer Relationship Management (CRM) software and a Quality Assurance Guide that Superior Pallets shares with its clients on request.

Superior Pallets has a 45,000-square-foot building that is a combination plant and warehouse. The end of May marked the beginning of some significant changes in the company’s pallet repair operations. Superior Pallets installed a Pallet Repair Systems (PRS) ‘nail-on-the-fly’ automated pallet repair line. In addition, the company added an Innovative Data Systems Pallet Track system that uses bar codes and other technology to capture and manage information about its pallet recycling operations. When Jeff talked to Pallet Enterprise in late May for this article, employees were still being trained on the new systems.

The PRS automated repair line replaced a semi-automated system of some significance. The old repair line was part of the business purchased by David, and it was the first pallet repair line designed by Clarence Leising, according to Jeff. Clarence, a sales rep for Eagle Metal Products, has a long history in pallet recycling management and is the author of Pallet Head, a hands-on management guide to pallet recycling.

The new PRS automated pallet repair line will be used exclusively to process GMA pallets. Other pallets are repaired at individual work stations.

If Superior Pallets gets a big order for new pallets of a particular size, it often contracts with other pallet companies that are equipped with automated nailing machines.

Superior Pallets can provide export pallets, too. Heat-treating is subcontracted to Integrated Thermal Solutions in Hamburg, N.Y. “They provide us with proper documentation,” said Jeff.

Approximately 97% of incoming pallet cores come from customers with regular contracts. Superior relies on a fleet of four tractors and 90 trailers to retrieve surplus pallets. Like other pallet recyclers, the company leaves empty trailers at customer locations, returning later to retrieve them when they are filled with pallets and to drop off another empty.

“A few customers will drop off here,” said Jeff, but most rely on Superior’s trailers and service.

Pallets are sorted before they are staged to the repair line. By sorting in advance, the repair line only gets the GMA pallets, and it only gets pallets that can be repaired or are potentially ‘ready-to-go.’ “Everything that comes in, we sort out to useable or unusable,” said Jeffrey.

In its lumber recycling operations, three Smart Products two-man bandsaw dismantlers are used to disassemble pallets. Used pallet parts are cut to length on PRS trim saws.

Safety is a top priority at Superior Pallets. New hires complete a safety training program – dubbed ‘Safely Superior’ — that was developed in-house. Emphasis on safety is reinforced with a daily practice; each employee reviews a safety topic before the start of a shift. Topics are the choice of the employee and may include machine guarding, proper lifting techniques or others. Also, supervisors conduct monthly safety meetings on topics mandated by the Occupational Safety and Health Administration (OSHA). On-site training and retraining of employees is augmented by a subscription the company has to KellerOnline, which provides easy access to trends and ideas in safety and OSHA updates.

The company has supplied a wide range of pallet sizes over the years. “The largest we’ve built is 180 inches long by 30 inches wide and the smallest is 19 inches by 24 inches,” said Jeff. Besides recycling pallets and making new, remanufactured and ‘combo’ pallets, Superior Pallets supplies plastic pallets, totes and dunnage.

A local company, VRI Sharpening Service in West Seneca, N.Y., services circular saw blades for Superior Pallets. “We buy our bandsaw blades from Sadowski’s,” said Jeff.

Jeff and his father are natives of Buffalo. Dave worked for Ryder Transportation for 22 years. In 1998 he went to work for the pallet business he eventually bought. He served as operations manager of the company. When the parent business began to sell off holdings, Dave decided to buy the pallet division and go into business for himself.

Jeffrey had experience working part-time for the former company. And he worked part-time for Superior Pallets, too, before joining the company full-time in 2001. He worked at the companies part-time while attending the University of Buffalo, where he earned a pre-law degree.

Jeff took a lot of business courses as part of his studies, and he had second thoughts about continuing for a law degree, especially when his father suggested joining the business. “After I graduated, he asked whether I would be interested,” Jeff recalled.

During his stint at the predecessor business, Jeffrey had come to enjoy the mill environment. He worked on a cut-up line that ran a Cornell gang saw and also assembled new pallets.

“I like working with my father,” said Jeff. “We get along very well. He knows the operations side, how to repair equipment.” Jeff and his father more or less split their duties, with Jeff handling financial and administrative tasks and Dave overseeing plant and logistical operations.

The Rotochopper MC-266 is powered by diesel engine. Scrap pallets are loaded into the grinder via forklift. The machine can grind whole scrap pallets, slabs, scrap used lumber, and other wood material. The MC-266 has an infeed opening 66 inches wide and 18 inches high. The machine is road legal when pulled by a tractor.

The MC-266 Rotochopper can grind enough scrap pallets — and color the mulch — to fill a 100-cubic-yard truck in about 40 minutes, according to the manufacturer. It is even faster grinding and coloring bark, producing 100 cubic yards in about 15 minutes.

“Rotochopper has been great for us,” said Jeff. “We’ve recommended it to three or four other companies. They’ve come to see it run. The folks at Rotochopper are absolutely wonderful. They’re phenomenal.”

Jeff and his father also share some leisure interests. “Both my father and I like traveling to Walt Disney World and golfing,” he said.

Click here to read about 3 specific advantages of plastic pallets instead of wooden pallets.

· Reduce global WARMING? · Save TREES?
· “GREEN” the planet?
· Create a Profit Center?

Believe it or not, the simple process of switching from pallets & skids made from wood can actually achieve all of the above goals. Even though the initial cost of plastic pallets is often higher than expenditures for the wooden variety, the total cost of acquisition (life cycle cost) clearly demonstrates that plastic wins the day. Also, there are potential “hidden” cost savings (cost avoidances) that result from a closer inspection of the waste stream from which a variety of plastics that are used for producing pallets are extracted.

For more information go to www.opprocon.com

This article features 3 main reasons why plastic pallets are superior to wooden pallets.  Click here to read this article.
Plastic Pallets & Plastic Export Pallets 
 
DACO offers a variety of sizes and types of plastic pallets such as single or double face, nestable and/or stackable, rackable and plastic export pallets for your work-in-process, storage and distribution applications. Companies every day are switching from wood to plastic pallets because they are recogizing the many benefits such as:

Reduction in Product Damage due to plastic pallets durability, consistent support, and smooth molded design. They won’t warp, shrink or change mass over time.
Reduction in Work Injuries - plastic pallets are lightweight and easy-to-handle and no splinters, nails, broken boards, etc. to deal with.
Improved Sanitation - most chemicals, etc will not compromise theses plastic pallets integrity, and they don’t absorb moisture; support the growth of mold, mildew or fungus; or harbor rodents or insects, approving these plastic export pallets for export use.
Pallet Racks are a complementary product that can be used with rackable styles of plastic pallets for storage of goods.
 
 Nine signs that plastic pallets may be right for you:

  1.  Product damage is a problem

  2.  Your application has sanitation requirements.

  3.  Pallet replacement and disposal costs are high or increasing

  4.  Your expendable packaging costs are high.

  5.  Pallet splinters and protruding nails are a problem.    

  6.  Substandard pallets are a frequent cause of equipment jams.

  7.  Pallet repair is becoming your second business.

  8.  Import shipments are delayed because of insect problems.

  9.  Your pallet costs are increasing.
 

Click here to read about the benefits of palletizing robots and why more and more companies are instituting them.

Palletizing Robots
 
It wasn’t that long ago that it was unheard of to see a robot at a packaging show. In recent years, however, show visitors find robots on display in virtually every aisle, usually performing palletizing operations.

Several reasons have driven the growth of the palletizing robot market. Basically, it comes down to economics. A robot can work faster and with greater consistency than a more expensive human operator, withstands harsh environments better and is largely immune to injury.

Since users are just beginning to recognize the benefits of robotic palletizing, rapid growth is expected for the next several years. ‘The market is just starting to be tapped,’ reports Michael Crane, product manager at ABB, New Berlin, WI.

Driving the interest in palletizing robots is the tight labor market and a need for greater process consistency. As it has become increasingly difficult to recruit qualified workers in the United States, ‘people are more willing to automate,’ says Mark Handelsman, director of engineering at FANUC Robotics North America, Inc., Rochester Hills, MI.

Robots also can offer the flexibility needed to efficiently handle the wide variety of distribution packaging consumer goods makers must provide to satisfy their retail customers. ‘The market is uneducated right now as to the flexibility robotic systems can offer,’ he adds.

Indicative of the flexibility required today is a recent installation by ABB of a five-robot system at a pasta manufacturer. To handle the output of 12 lines and accommodate various pallet sizes and case styles, two of the robots are configured for three in/three out operation, while the other three work on a two in/two out basis.

There are two types of robots used for palletizing, articulated and gantry. The latter are suspended from an overhead rack. ‘We’re seeing more applications for gantry robots because of product size and work area requirements,’ reports Mike Perreault, vice president at Midmac, a systems integrator based in St. Paul, MN. ‘If you have the vertical space, a gantry generally is more efficient in horizontal space utilization,’ he explains.

Encouraging the use of robots for palletizing are continuing improvements in capabilities related to payload, speed, flexibility, ease of operation and the ability to interface with line and plant controls.

Although the food and beverage industry has been a major user of palletizing robots, and interest from this sector continues to be strong, a growing number of units are being installed in plants producing personal-care, and paper products. Robots are particularly in demand in regulated industries like medical devices and pharmaceuticals where they can provide a higher level of cleanliness than a human operator and a greater degree of process control, thus simplifying the validation process, which ensures the system is operating within established parameters.

Some activity also is seen from soft goods, building material and petrochemical manufacturers. It should be noted that a high proportion of sales are generated by first-time customers.

In addition, ‘We’re seeing a lot greater interest on the distribution side,’ says Handelsman. After watching the U.S. Postal Service (USPS) make a $101-million commitment to robotics in 1999, many companies, which are striving to reduce logistics and handling costs, are taking a look at robotic palletizing.

Worker safety, quality and cost control are the drivers behind the USPS investment. When the project is complete, trays of sorted mail will be loaded by robot into all-purpose mail containers for transport by truck or air. Although the material-handling system may vary depending on the building, the robotic cells and gripper configuration will be identical.

Gantry robots from ABB move mail in open trays, as well as sleeved
and strapped trays. With their denser, rectangular footprint, gantry systems
are compatible with the space limitations encountered in some older USPS facilities.

The robotic project is one step toward a ‘lights-out’ mail processing facility, which is being prototyped in Ft. Myers, FL. ‘The robots will play an integral role in this facility,’ says John Weller, program manager, USPS Material Handling Research and Analysis Engineering.

A demand for high throughput has driven improvements in controls as well as interest in heavier payloads so product can be moved by the tier instead of case by case. FANUC Robotics, for example, has developed the M-410iWW, capable of handling payloads up to 880 pounds at more than 12 cycles per minute.

Heavier payloads also are spurring interest in gantry designs, which traditionally have been able to move more weight at faster speeds than an articulated robot. Toronto-based RMT Engineering Ltd. has installed gantry units capable of handling 100 cases per minute because it moves layers of cases as a unit rather than individual cases.

Another in-demand feature is the ability to interface with plant networks and different control systems. An example of a state-of-the-art system is a highly automated, five-robot system recently installed by FANUC. The units are controlled by a personal computer, which, in turn, interfaces with the plant control system, which resides on an IBM AS400 computer.
A similar interface between robot and plant business system is part of an upgrade to a two-year-old RL 80 palletizing robot from Reis Robotics, Elgin, IL, at Sandvik Chemical Products, Bristol, VA. Sandvik’s goal is to track inventory of its mine bolt resins, a two-component polyester-based material used to strengthen mine roofs and prevent cave-ins. When the system was being designed initially, ‘We thought the idea of tracking inventory was interesting, but we didn’t think it would be necessary,’ recalls Ken Monyak, production manager. ‘Now that we understand how the system works, that’s what we want to do,’ he adds.

Tracking will be accomplished by automatically updating inventory records each time the robot sets a corrugated box of product on a pallet. Since boxes could be dropped or rejected due to labeling problems, ‘the robot only counts boxes it successfully places on a pallet,’ he explains.

In action, 40- and 60-pound boxes conveyed from Building 2 to Building 3 at Sandvik trip a photoeye, which starts a bar code scanner. The scanner sends label data including lot and sequential box number to the robot. The robot determines which of six pallet positions the product belongs in, the nest pattern and where the next box should be placed on the load, then picks up the case, sets it in position and transmits the part number to a database in a linked PC. As soon as interface software is written, the PC will be able to transmit case counts directly to the plant’s AS400.

Neater looking, more tightly stacked pallet loads was an
unexpected benefit of Sandvik’s transition to robotic palletizing.

Harsh environments are another area where robotic palletizers make sense. FANUC is preparing to install what it believes will be the first North American placement of a palletizing robot in a freezer. Although the industry has been slow to accept robots in this setting, there are numerous advantages. First and foremost, it removes people from the freezer, an area where the cold temperatures make it more difficult to work safely and require added manpower to compensate for the more frequent breaks personnel need. This freezer installation at a large ice cream manufacturer will join one up and running for several months at a French fry producer in Europe.

Protective ‘coat’ helps FANUC M-410i
withstand freezer conditions down to -30F

Keeping some end users from considering a robot is a lack of familiarity with its control and programming. ‘That’s why we have worked very hard to make the systems easy to set up,’ says Handelsman. For example, the operator interface features palletizing rather than robotic terminology. The idea is to ‘make it as simple as possible on the operator level,’ he adds.

To this end, ABB has developed PC-based software called PalletMaster and a color touch screen operator interface. To simplify programming of the robot itself, ABB offers another Windows-based program, PalletWizard. Both reside on the FlexPalletizer cell controller PC and interface with the robot controller itself.

Palletizing robots generally appeal to end users with mid-range needs. Low-end users often assume a robotic system is beyond their budget. While this may have been true a few years ago, prices, in general, have declined as hardware costs have dropped, and software has become more plug-and-play.

At the other end of the scale, high-volume palletizing still tends to be the province of hard automation. However, gantry robots like those from RMT are capable of handling many different products at relatively high speeds and can be equipped with a bar code reader so cases can be sorted as well as palletized.

Such multitasking is another feature robot users are demanding. Moving further upstream in the process, some systems like those designed by Midmac use a single robot to load the case before palletizing it

Other developments have to do with end effectors capable of handling a wide variety of case styles and devices to protect the robot and its human coworkers. Applied Robotics, Inc., Glenville, NY, for example, offers QuickSTOP collision sensors, which shut down the work cell and deflate to absorb the impact, thus minimizing damage to tooling and product.

Also becoming more advanced are the safety systems, which ensure no personnel get in the way of a working robot. Work cell perimeter guards like Smartscan L- and T-shaped light curtain units from Applied Robotics are sophisticated enough to differentiate between a pallet and a person. When a pallet is detected, a self muting feature allows it to pass, however, if a person tries to enter the work cell, equipment movement is halted in a split second.

This new washer is able to treat plastic pallets while maintaining hygiene controls.  Read more about this
here.

19-Jun-2008 - Increased equipment capacity enables faster crate washing and drying service for returnable transit packaging (RTP) users, claims PHS Teacrate.

The UK crate rental company said that it has installed a new washer and dryer with 24/7 operational capacity at its facility in the Midlands to streamline RTP crate washing and to cater to the growing demand from large food processors.

“Our new washer is able to treat plastic pallets, trays and crates,” Caroline Williams from PHS Teacrate told FoodProductionDaily.com.  “All RTP items are passed through a new drying section, which cuts down on turnaround time and prevents water damage to products.”
 
Hygiene controls

She said that UK food processors are increasingly outsourcing their pallet and crate equipment washing due to the strict hygiene measures and protocols that the large multiples insist on.

The crate rental company said that it offers a complete quality control programme as part of its cleaning procedure, including random microbial swab testing.
Environmental impact

According to Williams, RTP is fast replacing cardboard as the preferred carrier for transporting food products such as meat, poultry, baked goods and fresh produce, as it offers an easy-to-manage solution with controlled, predictable costs, and allows processors to meet seasonal peaks.

She said that RTP packaging also has minimal environmental impact:

“The life span of RTP equipment typically is five to ten years, which enables multiple trips through the supply chain. Cardboard products can only be used two to three times before the waste has to go to landfill, resulting in expensive waste disposal costs for the customer,” said Williams.

“RTP also allows more efficient loads on vehicles, providing better space utilisation than cardboard and better protection in transit, which results in less damage to stock,” added Williams.

Williams said that its new washer will help processors using RTP packaging cope with the increased summer demand for barbecue goods.

PHS Teacrate’s services include crate sale and rental as well as assets tracking.
 
 

Miller Brewing increased their order of plastic pallets by 8% this year with Greystone Logistics.  Miller Brewing has been using 100% recycled plastic shipping pallets for the eighth consecutive year. You can read more about this here.   

Greystone Logistics Announces Purchase Order With Miller Brewing
 
June 11, 2008: 06:00 AM EST

Greystone Logistics (OTCBB: GLGI) recently received an annual purchase order from Miller Brewing for 100% recycled plastic pallets for the eighth consecutive year. The order volume is an 8% increase over the previous year.

“We are proud to provide Miller Brewing all their case goods pallets,” said Warren Kruger, CEO of Greystone Logistics. “Miller was an early adaptor of recycled plastic pallets and is a leader in promoting sustainability across the world. Other efforts are being made to reduce wood usage. We are now focusing our efforts on the previously announced 100% recycled plastic keg pallet which has tested extremely well in their breweries and will be ready for production soon.”

Greystone Logistics is a rapidly growing manufacturing and leasing company that designs, manufactures, sells and leases high quality pallets made from recycled plastic that provide logistical solutions needed by a wide range of industries such as the food and beverage, automotive, chemical, pharmaceutical and consumer product industries. Greystone’s technology, including that used in its injection molding equipment, proprietary blend of recycled petrochemical resins and patented pallet designs allow production of high quality pallets at a lower cost than competitors. Greystone utilizes post industrial and consumer scrap such as plastic barrels, milk jugs, plastic shavings, flowerpots and car bumpers. The recycled plastic for its pallets helps control material costs while reducing environmental waste. Using recycled plastic instead of wood helps prevent deforestation and provides cost advantages over users of virgin plastic resin.

This press release includes certain statements that may be deemed “forward-looking statements” within the meaning of the federal securities laws. All statements, other than statements of historical facts that address activities, events or developments that the Company expects, believes or anticipates will or may occur in the future, including the potential sales of pallets or other possible business developments are forward-looking statements. Such statements are subject to a number of assumptions, risks and uncertainties, including the ability of the company to continue as a going concern. Actual results may vary materially from the forward-looking statements. For a list of certain material risks relating to Greystone and its products, see Greystone’s Form 10-KSB for the period ended May 31, 2007. For additional information in relation to Greystone and its products see Form 10-QSB for period ended February 29, 2008.

Click here to read about the different kinds of pallet lifts available from Easy Rack.
Thursday, June 12, 2008
Pallet Lifters
Hydraulic Pallet Lifts are intended to assist during construction work, ship loading, unpaved storage areas, open-top trucks and even barges. Some pallet lifters use forks that slide underneath pallets, allowing you to lift and move it from workstation to workstation. Manual pallet lifts such as this unit feature solid steel construction tapered forks to allow easy access under pallets. The unit’s main support contains handles that allow personnel to easily steer and control the unit. The large, square head at the top of the unit acts as a counterweight that keeps the unit level without a load. The manual unit meets ASME B30.20 Standard 1993. A certificate is shipped out with every unit stating that it has been tested.

Other pallet lifters use electronic motors to elevate, rotate, and tilt pallets for precise maneuvering and safe rapid transport. Easy Rack offers three models from which you can choose.

Low Profile “U” Type Electric Pallet Lift Table
The open center on the “U” Type Electric Pallet Lifter Tables allows a pallet truck to place a load on the platform. This ergonomic lift equipment features an external power pack equipped with a pressure relief valve that prevents overloading. It also has a flow control valve that controls the lowering speed. A remote power pack, complete with a steel cover, protects the motor from dust and debris. You can raise and lower the pallet lifting table with UP and DOWN push-buttons on the 24V control box. Safety features include electric toe guards, velocity fuse in cylinders, safety maintenance props and an emergency stop button on the control box.

Note: The power lifting table can only be used with skids or open bottom containers when being loaded with a pallet jack. The opening in the deck is 21 7/8″W x 41 1/4″L, so the pallet truck needs to be 20″W or less for this table to work. Standard closed bottom pallets would need to be loaded with a fork lift or straddle type lifter.

Portable Pallet Lifter and Inverter
Rotate and transfer pallets with Easy Rack’s Portable Pallet Lifter and Inverter. This convenient, easy to use pallet lift is a must have in your shop, loading dock, or warehouse. When using the PPLI, simply place the unit’s lower forks underneath the bottom pallet, lower the top forks to secure the pallet’s inner contents, and lift the pallet up 90 degrees. At this point, operators can manually rotate the load 180 degrees where it will stop and latch into place automatically. This will bring the top pallet into the lower position, effectively inverting your load. Tilt the load down, and it’s ready for transport, or to be lowered to the ground. Because the PPLI utilizes outriggers, only open bottom pallets and skids are compatible with the design.

The dc power lift and drive makes operations safe and efficient, and the units built in battery charger provide maximum convenience. Standard features on the Easy Rack Pallet Lift and Inverter include a key operated, on/off switch, forward and reverse butterfly controls, and easy to use hand controls for the lift and tilt function. The portable pallet lift also features chrome plated cylinders, steel outriggers, and an emergency stop belly switch for added safety. The unit’s low-profile design allows the operator to stand on the rider platform and steer the load from workstation to workstation quickly and easily Convenient and efficient, Easy Rack’s pallet inverter is ideal for use in loading dock areas, and warehouses as a power pallet truck, power tilter, or turntable. Let this sturdy innovative unit go to work for you.

Easy Rack Pallet Inverter
This pallet lifter has been engineered to reduce your costs in production, storage, retrieval and distribution. Its 180° rotation makes pallet exchange quick and simple while reducing product damage. It enables easy load transfer from wood pallet to plastic pallet, slip sheet or rental pallet. It is ideal for loading and unloading with a fork truck. The pallet inverter lift features safety rails and guards, an. Units can be loaded and unloaded easily with a fork truck.

Other features include:

· Easy load transfer from wood pallet to plastic pallet, slip sheet or rental pallet.
· Pendant control is easily accessible to lift truck operator.
· Free standing 180 degree Inverter with single clamping plate.

This pallet inverter and lift is ideal for the quick, efficient removal of broken or damaged product, and it also significantly helps reduce back injuries in the workplace.

Easy Rack carries commercial shelving, material handling equipment, commercial lighting, pallet trucks, used pallet racks, and modular prefab buildings available nationwide. If you can not find the dock equipment you are looking for call us toll free at 1-888-776-3720 and we will find it for you.