A manual palletizing process is slower and can’t keep up with the growing demand
A manual palletizing process is slower and can’t keep up with the growing demand
When done manually, palletizing can quickly become a source of inefficiency that affects both productivity and reliability. Workers face repetitive heavy lifting, which increases fatigue and the risk of injury, while errors in stacking can compromise product safety and consistency.
Over time, these challenges not only slow down workflows but also prevent businesses from keeping pace with demand or adapting to market changes with agility. This is exactly where an optimized palletizing process can make the difference, bridging the gap between manual limits and industrial growth.
From bottlenecks to efficiency
An Italian company specialized in book manufacturing was facing a rising demand but struggled with delays and operational bottlenecks. The manual handling of the palletizing process made workflows slower and harder to scale. To sustain business growth, the company needed a smarter solution.
Solema stepped in. We introduced an automated palletizing process designed to streamline operations. Our team installed palletizers endowed with a timing station at the entrance, an accumulating conveyor, automatic storage for empty pallets and an automatic device for feeding of the slip-sheets. The continuous jogging of the product during the different transition inside the machine, the simplicity of movements through linear and real-time monitoring enable the company to reduce downtime and increase consistency across shifts, as well as ensure precise layer formation and optimized load stability.
Tasks that previously required significant manual effort became smooth and safer for workers. With Solema expertise, what once was a production obstacle became a strategic advantage, helping the company transform inefficiencies into measurable progress and reliability across every stage of its supply chain.
From bottlenecks to efficiency
Our automated palletizing solutions are designed to combine flexibility with reliability, adapting to the specific needs of industrial environments. For this project, our engineers developed a tailored solution capable of handling different book formats. We installed Pluton to palletize book blocks and catalogues, together with our machines for stacking and feeding operations. Everything was connected through a complete transportation system.In just six months, the company obtained some great benefits:
- productivity increase: with an average 25% pr shift;
- reduction of production line interruptions by about 30%;
- safer workplace: with 40% fewer repetitive lifting operations for employees;
- less labor required: with 40% fewer people requested to operate the line/shift;
- greater accuracy and quality: lowering stacking errors by nearly 25% and enhancing quality of 50%.
We focused on precision and automation. This demonstrates how a well-engineered palletizing process can turn everyday logistics into a streamlined operation for long-term success. With over 40 years of experience, Solema has developed modular solutions that help companies scale their operations and meet the growing demands of their customers. If you want more information about our palletizing automation systems, visit our website and contact us to request a quote.