Line Automation to Product Inversion to Improve Workflow

Overview
When Cherry’s Industrial Equipment introduced the stand-alone 180° Pallet Inverter in 1983, it could do just that: invert. Over the years, we have had the opportunity to customize our machines to take on any task our customers might need. For our customers at Graphic Packaging, who are a leading corrugated packaging manufacturer, we were fortunate to work with them on two Inverter projects. They print boxes for products such as cereal and toothpaste, and an automated pallet inverter helps make 180-degree inversion a much simpler, quicker process.


The Challenge
Usually, moving a product doesn’t have to be too exact. As long as the load is carefully placed, it can be inverted with no problem. However, to ensure accurate printing and die-cutting, a load needs to be properly oriented. Originally, a small group of employees would perform this task manually, taking small stacks of boxes and flipping them by hand. This is as inefficient as it is dangerous for the employees — many reported to have experienced carpal tunnel issues from the process.
In hopes of making their process more ergonomic, they replaced their manual process with standalone machines, but these came with challenges. When using the machine, there still needed to be workers who could do some tasks the semi-automated system couldn’t complete. Coordinated forklift movements were required for this operation, first to pick up the printed material near the presses, and then a second unit would bring the load to the machine for inversion. In addition, the corrugated packaging that was being inverted was very slippery, unstable, and difficult to move over long distances. This requires the use of stretch film or banding, which further complicates the process even more.
To make improvements in their process we had to consider the following: One, getting rid of the need to band the load and use stretch film prior to inversion. Two, try and reduce the number of touches needed, both by human hand and forklift, throughout the plant. Third, the implementation of a system that would invert automatically without an operator being present. All these goals for the new system were connected, couldn’t be done without another, and would lead to an ergonomic solution that would positively impact their workers while keeping production up.


The Solution
The key to implementing a successful pallet inversion system is to ensure the load will always have stability. At Cherry’s, it’s a guarantee our automated solutions will provide that stability to the product, allowing it to be moved between pallets while also having minimal shifting.  This was especially important for Graphic Packaging, as any movement would cause problems with gluing and die-cutting down the production line.
For example, the load might need to be switched from a wooden pallet to a plastic pallet. Sometimes, the load may not even be on a pallet at all but rather on a slip sheet. Our task was to make the system flexible enough to adhere to any task it might face, while still giving the load the stability it needed.


The Results
n order to solve this, we used a pallet gripping system. It was implemented in the Pallet Inverter itself, and it held the pallet in place as it would flip. This system ensures that the load is stable. The gripping system could also grip the pallet for other uses as well. When inverted, the arms would hold the pallet. This allowed for the pallet to then be switched with another. That same pallet would then be placed onto the next load that entered the machine, to then be inverted. Essentially, if you fed the machine with just one pallet at the very beginning of the operating period, it would continue to use a pallet supplied from the previous loads.
Two of the problems we were faced with were tackled because of this: The operator no longer had to be present to run the system, and the number of touches became less without having to worry about switching pallets manually.


Conclusion
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 847-443-3861 or submit our online contact form. We’ll answer any questions you may have and suggest the best solutions for your facility.