Fully Automated Crate Handling and Palletizing System

The project delivers a fully automated return crate stacking and palletizing system, covering every stage from unloading roll cages and pallets to the final wrapped pallet ready for dispatch.

The system automatically unloads roll cages — the operator ensures that each cage contains only one box type before loading. The roll cage is transferred to the input conveyor, buffered, and positioned for unloading, where pneumatic pushers transfer both stacks out of the cage. Empty roll cages are then automatically returned out of the cell.

For pallet unloading, operators place partial stacks onto receiving conveyors serving as buffers before merging. Each box type has a dedicated combiner unit, which forms full stacks using laser-guided measurement. For Transbox crates, the system automatically checks and corrects the stacking orientation by rotating 180° if necessary.

Full stacks are conveyed to buffer conveyors and then transferred by a shuttle car to the robotic palletizing station. Palletizing is handled by an ABB IRB 710 robot, ensuring stable and precise placement.

Each pallet is wrapped according to pre-set recipes by a high-quality wrapping machine. Wrapped pallets exit automatically for downstream logistics.

The system’s frame is stainless steel, all drives are frequency-controlled, and automation is powered by a Siemens PLC with ProfiNet network, decentralized I/O, multi-zone safety logic, and CE certification. Remote connection enables rapid diagnostics and support.

This turnkey automation solution ensures maximum efficienc and reliability in industrial crate handling for food and logistics operations.