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BOX PALLET AND TRAY DISPLAY FORMING

Box pallet displays forming system:

The box pallet display forming system erects the pallet like carton display automatically by closing the bottom part with hot melt and folding the central part. Subsequently, the display is glued on the wooden pallet or, as an alternative, is kept steady by inserting a cardboard piece inside. To automate and accelerate these operations, it could be necessary the partial review of the packaging.

The box pallet displays can have various dimensions and can be of 2 types:

  • TYPE 1: “classic” box pallet with bottom part closure by hot melt and then glued on wooden pallet (on the left);

  • TYPE 2: box pallet with cardboard piece insertion after forming (on the right).

The box pallet forming system is generally connected with the display filling phase.

The area includes:

  • one silos with minimum capacity of 50 cartons, with easy adjustment so to handle both types of box pallet displays;

  • one silos for the mini-pallets (600 x 400 mm, equivalent to 1/4 of a Europallet) that can contain a pile of 20 pieces.

The box pallet display forming system can form, in average, 20 box pallets/hour.

Trays / displays forming system:

The tray / display forming system erects the carton tray automatically. Trays / displays can be of different types and sizes.

During tray erection, the lateral flaps are left open so to allow the product insertion during pick & place phase. After filling, in a following glueing station, the lateral flaps will be closed.

The system includes a silos containing a few hundreds of flat cartons and forms in average 120-150 trays/hour.

The box pallet and tray displays types can be made with:

  • single-wave or double-wave carton;

  • printed single-wave or double-wave carton.

Filling system (pick & place):

The pick & place area automatically places the products into the box pallet or tray displays. The pick & place robotic system, located after the box pallet and tray displays forming area, is able to handle different types of products, such as:

  • biscuits bags;

  • flowpacked packs;

  • glass jars in multipacks, matrix 2x1 / 3x1 / 2x2 / 3x2;

  • etc.

The pick & place area is able to fill in:

  • box pallet from 1/4 pallet (600x400mm);

  • trays / displays from 1/4 pallet (600x400mm).

Box pallets and trays arrive to the system already formed and ready to be filled in. The automatic handling of box pallets and display trays can be adjusted easily according to the size. An operator prepares the products manually to be inserted into the box pallet / tray and loads them into the pick & place feeding unit (such as a conveyor). Subsequently, the products are picked up and placed by an anthropomorphous robot into the box pallet / tray. Depending on the type of product that has to be handled, there will be a buffer station for the automatic insertion of interlayer cardboards, or reinforcement cartons, or bee-nest product separators. Empty box pallet / trays coming from the forming area are automatically placed inside the filling area and (once pick & place and flaps closure by hot melt operations are carried out) accumulated to be subsequently stacked by the two robotic arms.

Stacking system:

The box pallet is already equipped with a mini-pallet or with a carton piece during the erection phase. Therefore, this one will not run in the stacking system.

The trays / displays, once filled-in with the requested product, are stacked at output in the pick & place area. Then the system closes the trays upper part by glueing the lateral flaps and are placed on the wooden mini-pallet coming from the forming area. The various operations are set on a central electrical rack for handling and control.

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