Product Inversion Automation
An automated pallet inverter makes simple 180 degree inversion a much simpler, quicker process. We completed two different pallet inversion projects for Graphic Packaging, a leading corrugated packaging manufacturer. They print boxes for products such as cereal and toothpaste.
The Challenge
To ensure accurate printing and die-cutting, a box needs to be properly oriented. Originally, a small group of employees would perform this task manually. They’d take a small stack of boxes and flip it over with their hands, which was both inefficient and dangerous for the employees — many reported experiencing carpal tunnel issues.
Over the years, both plants replaced the manual process with standalone machines, but these came with their own challenges. Coordinated forklift movements were required for this operation as one would pick up of the printed material near the presses and then a second unit would bring the load to the machine for inversion. Further complicating the process is that the corrugated packaging can be very slippery, unstable and difficult to move over long distances, requiring stretch film or banding which further complicated the process.
Important considerations for process improvement for the customer included: elimination of banding and stretch film prior to inversion, reducing the number of touches and movements by forklifts throughout the plant and finally a system that would invert the loads automatically without an operator being present.
Our Solutions
The key to implementing a successful pallet inversion system is to ensure a stable load. Our automated solutions provide stability for the product to easily move between pallets with minimal shifting. Any product movement could cause problems with gluing and die-cutting later down the line.
In one case, it would go from one pallet to another pallet. In another situation, it would travel down the conveyor on a slip sheet, so our product inversion solution would have to flip it over without the security of a pallet beneath it.
We used a gripping system in the pallet machine to grip both sides of the load. This system ensures stability during inversion, which helps transfer the product securely to the bottom pallet. The machine would then use the pallet on top for the next load. Essentially, you’d feed that system with a pallet once, and it would continue to use a pallet supplied from the previous loads same one. With loads that used slip sheets, we had to be especially sure we could compress them without allowing the loads to shift.
To ensure the machine wouldn’t cycle back empty, we also developed a folding side wall that selectively allows products to pass through. Here’s how it works:
- For loads requiring inversion: The walls fully extend to stop the load while the machine inverts the product. They then open back up to let the product through.
- For loads that do not require inversion: The wall remains folded to let the product through.
After a successful installation of our solutions, the customer increased productivity while reducing employee headcount with a fully automatic system, which was crucial for the corrugated packaging industry throughout the pandemic.
Browse Pallet Inversion Systems From Cherry’s Industrial Equipment
We strive to help companies meet their full productivity potential. To help achieve your goals, browse our selection of pallet inversion systems online to see what we offer, or reach out to discuss a custom solution.
To request a quote or get more information, feel free to call us at 800-350-0011 or submit our online contact form. We’ll answer any questions you may have and suggest the best solutions for your facility.