Palletizer Rebuild - Beverage Manufacturer

PROBLEM: Operators were manually palletizing 2.5 and 5 gallon packages on a beverage packaging line. The speed of the line was greatly limited by the manual palletizing. Ergonomic issues were also a concern, since the packages weigh between 30 and 60 pounds each. A new palletizer was ruled out due to the high cost, but an older palletizer was available for use. The customer procured this used palletizer, which was in poor condition and required extensive refurbishment before it could be utilized.

SOLUTION: ABCO rebuilt the palletizer and installed it on the line as part of a project that also included the installation of additional powered conveyor and an automatic stretchwrapper. This equipment automated the line and enabled it to run much faster while eliminating most of the ergonomic concerns associated with line operation. The used palletizer was also designed to handle only 5 gallon packages. ABCO modified this machine so it could palletize both 2.5 and 5 gallon packages.

ABCO stripped down the palletizer and removed all machine components. The frame was sandblasted, primed, and repainted. All worn parts were replaced on the machine. This included the addition of new bearings, rollers, chains, sprockets and shafts. The reused parts were cleaned before reassembly. The palletizer controls were also upgraded from relay to PLC control. Photoeyes and other electrical components were replaced as required and all old wiring was removed from the machine. The machine was completely rewired and a new control panel was added.

ABCO provided a low cost alternative to the purchase of a new palletizer. The rebuilt palletizer was significantly less than a new palletizer and the rebuild took only 8 weeks to complete. The machine was also modified to provide the increased flexibility to palletize both 2.5 and 5 gallon packages. This palletizer continues to provide trouble free operation for the plant.