Until 2021, an Australian water bottling company’s manual palletizing process had become the norm. Its warehouse employees tediously palletized 10-liter jugs and wrapped them by hand, believing there were few options outside of their current process despite how labor-intensive and time-consuming it was.
The company had been searching for a more efficient solution that would match the conditions of its facilities. While presented with many options, the tight spacing in their facility made a small footprint essential.
Their search led them directly to TopTier, an American-based palletizing vendor. Guided by Dave Snelson, TopTier’s Director of Sales, they began working to create a solution for the Australian company, overcoming several challenges.
Overcoming Initial Hurdles & Customized Solutions
The Australian company’s primary concern was whether TopTier’s palletizers could handle their specific product within a small footprint. The 10-liter water jugs needed to be nested from one layer to the next, a crucial task for stable palletization. TopTier requested products to be tested in their US location to guarantee feasibility. TopTier tested products and successfully demonstrated the capability even with a machine that was not fully equipped. This success led to a formal quotation for the L7 low-infeed palletizer, designed to palletize 21 bottles per layer at 22 per minute. TopTier put the build cycle for their machine into motion.
Early in the build process, the bottling company approached Snelson with a new challenge: they needed the TopTier machine to palletize on a smaller ALDI pallet, measuring only 23 inches wide by 30.5 inches long. This size was significantly smaller than any pallet TopTier had handled before.
Seeing an opportunity to kill two birds with one stone, the team designed an insert for the pallet dispenser, guiding mechanisms for the load build area, and custom change parts for the layer head and tier sheet inserter. Despite the challenges, TopTier delivered a solution that effectively handled the larger 48 by 48 pallets and the smaller ALDI pallets.
Unlocking the Advantages of Automation
The transition from manual to automated palletizing brought substantial benefits to the company. Manual palletizing of 10-liter, 25-pound jugs was not only strenuous but also made it challenging to find consistent labor. The automation provided by TopTier not only saved labor costs but also allowed the company to repurpose existing staff to more strategic roles within the plant. Additionally, the concurrent stretch wrapping capability of the TopTier palletizer offered a significant advantage. Its compact footprint fits well within the company's spatial constraints, making it an ideal solution.
A year after the project was initiated, the machine was installed, and the reasons for choosing TopTier and trusting their solution were clear: their concurrent stretch wrapping capabilities, flexibility and ability to handle further challenges, and the compact footprint of their equipment were unmatched by competitors.
Industry Innovations & Learnings
Powerful insights can be observed from the collaboration between TopTier and the Australian bottled water company. TopTier demonstrated remarkable versatility in palletizing by creating a machine capable of handling large and small pallets, a crucial capability for businesses with diverse packaging needs. Further, TopTier effectively nested and stretch-wrapped giant jugs of water, a common requirement in the water bottling industry, showcasing their ability to meet industry-specific challenges and setting a standard for future innovations.
The Australian water bottling company's flexibility and collaborative approach were essential to overcoming their challenges. Their close cooperation with TopTier allowed for continuous adaptation and refinement, leading to the development of the ideal solution.
Reimagining Palletizing with TopTier
TopTier's palletizers excel with products ranging in base dimensions from as small as 6 inches by 6 inches to 28 inches by 18 inches. Modifications such as replacing conveyor rollers with belts are necessary for smaller products to provide proper support during palletization. With these adjustments, TopTier can handle products as small as 4 3/8 inches by 4 3/8 inches, showcasing their adaptability and engineering prowess.
In the complex world of logistics and manufacturing, TopTier stands as a beacon of innovation by providing comprehensive palletizing solutions. Their automated systems utilize advanced technology to optimize product placement on pallets based on factors such as box dimensions, weight, and orientation. This automation increases productivity while significantly reducing worker fatigue and the risk of injury.
TopTier offers a range of specialized palletizing products that seamlessly integrate into existing workflows, enhancing operational efficiency. Their palletizing systems, which include industrial robots and high-speed handling capabilities, are built with a focus on performance, reliability, and ease of use, ensuring they add substantial value to operations.
TopTier’s commitment to innovation and efficiency is evident in its ability to adapt to diverse operational needs. By continuously advancing its technology, it remains at the forefront of the industry, delivering solutions that drive success for its clients. Their comprehensive approach to palletizing improves operational efficiency and productivity and enhances workplace safety, setting a benchmark for the industry.
Conclusion: A Success Story
The partnership between TopTier and the Australian water bottling company exemplifies the benefits of automation in palletizing processes. By addressing unique challenges and delivering a tailored solution, TopTier enhanced productivity and efficiency and set a benchmark for innovation in the industry. Other companies can learn from this success story, recognizing the importance of flexibility, collaboration, and the right technology in achieving operational excellence.
