ACPaQ: Fast and reliable automated mixed case palletizer

ACPaQ stands for Automated Case Picking / Packing + SynQ (Software). It is a robotic and data-driven case palletizer solution for store-ready mixed case palletizing. 

The solution takes single SKU inbound stock pallets and builds them into mixed SKU outbound order pallets in a desired sequence. 

ACPaQ is a highly flexible solution, with semi-automated modules available to suit different requirements. Further automation, such as ROWPaQ cells, can then easily be added at a later stage, so that the solution can grow and become fully automated in line with a business’ growth.

The solution is scalable for mid-size, and large distribution centers handling up to 500,000 cases per day. Swisslog’s SynQ palletizing software allows you to customize the palletizing order to increase efficiency during in-store replenishment.

• Technical performance: Up to 1,000 cases per hour/per robot
• Product range: Almost all types of cartons, plastic wrapped packages or bins
• Small tray load: Up to 24 kg
• Large tray load: Up to 35 kg
• Temperature range: Chilled environment: from 0°C to 4°C (32°F to 40°F)
• Ambient environment: from 5°C to 40°C (41° F to 104°F)
• Pallets: Various types of pallets and roll cages

• ACPaQ handles a wider range of products, compared with other automation solutions.
• ACPaQ uses leading KUKA robots that provide system reliability and advanced functionality.
• ACPaQ is an efficient fully automated process. Each pallet is always built stable, correct and store-friendly, based on individual store planograms, reducing your in-store shelf refilling costs.
• ACPaQ uses a fully tray-based system, which delivers gentle, safe, and reliable handling regardless of the base and sides of the case being moved.
• Using multi-axis robotic grippers, ACPaQ can handle multiple cases per move and therefore has a higher throughput capability than any other automation provider.
• Modular design is scalable for mid-size and large distribution centers. This allows growing businesses and companies to increase throughput capacity and to handle peak demands efficiently.
• Full integration of storage system, components and Swisslog’s SynQ software ensures reliable and transparent operation. SynQ also sequences pallets and takes can take into consideration any unique requirements, including height restrictions, fragile cases, or dangerous goods.

• Efficient fully automated process. Each pallet is always built stable, correct, and store-friendly, reducing your in-store costs at shelf refilling.
• Robot palletizing using advanced KUKA robots increases throughput and improves the picking quality of your order pallet.
• Unique grippers with four forks for gentle, simultaneous handling of multiple products, palletizing with high performance of up to 1,000 units per hour. 
• Modular design is scalable for small, mid-size and large distribution centers. This allows growing business and companies to increase throughput capacity and to handle peak demands efficiently.
• Tray based solution allows you to handle a wide range of products and gives you flexibility for future changes in product packaging.
• Full integration of storage system, components, and Swisslog’s SynQ software ensures reliable and transparent operation.

a) Goods arrive in homogenous pallets

b) They are automatically

i. stored in the pallet storage, or

ii. depalletized layer by layer by a depalletizing robot for replenishment

c) The depalletizing robot positions the pallet layers on a conveyor belt

d) The layers are descrambled

e) The single cases are loaded automatically into trays

a) The cases are stored in a multi-level storage served by CycloneCarrier for case buffering

b) After order assignment, the cases are released from the case buffer and are put into the right sequence by the sequencer

c) The single cases are unloaded from the trays

a) The conveyor between the tray unloader and the palletizer forms a row of cases according to the palletizing pattern, which is released when the pick-up conveyor is empty

b) ROWPaQ palletizes up to four cases in a single movement allowing a row-by-row principle

c) The order pallets are load-secured by a wrapping machine in the robot station

d) The secured pallet is labelled and transported to the despatching area