Pallet Transportation Technologies

When it comes to automatically moving pallets from one spot to another, most logistics professionals know there are several options available like conveyors, transfer cars, Automatic Guided Vehicles (AGVs), and perhaps another mouse trap or two. The variables are many and guidance is sometimes lacking, so we wanted to spend some time with two of the go-to experts at Stoecklin when it comes to pallet transportation technology.

Emanuel Rippstein, Product Manager for Conveyor Systems, and Bernd Krebs, Product Manager for AGVs, are both located at the Laufen, Switzerland at headquarters of Stoecklin Logistics. Emanuel and Bernd each have more than 20 years of experience in the logistics and warehousing industry, the last several with Stoecklin. Emanuel and Bernd share their expertise by answering a few questions about the benefits of and considerations of conveyor systems and AGVs for pallet transportation applications.

1. Before we start talking about the details of different technologies can you both talk a little bit about why a company would look at using automation to move pallets rather than simply using an operator on forklift?

Emanuel Rippstein: One of the main reasons for automation is to increase efficiency. In many situations, direct labor is a significant cost driver in the work process. That is why automation is a great solution to optimize simple work processes. This is especially true for warehouses and order picking. Another reason why companies are increasingly looking into automation is that accuracy and traceability increase significantly. The more humans are involved in a process, the higher the likelihood for errors.

Bernd Krebs: There are several reasons why automated pallet transport, under given circumstances, makes sense. The first is that manual forklifts tie up manpower, so employees are relieved from repetitive or constant transport processes by automated transportation with AGVs. Ideally, the employees can use their time to perform more complicated or more demanding activities and only be used for special transport movements. In addition, automated transport can save considerable labor costs in the long run, so that the system, depending on the complexity, pays for itself in the short or medium term.

Although AGVs are slower than manual forklifts, they provide a more uniform and above all more material-friendly transport process with lower maintenance costs, compared to manual forklifts. Further, the number of accidents and damage to property and infrastructure decreases significantly. AGVs can be used in shift operations without requiring or consuming additional resources. Additionally, they require none of the usual downtime that a traditional workforce has such as illness, vacation, etc.

2. We all know that AGVs allow for the automatic movement of pallets without creating a permanent obstruction. What other factors might be a consideration when deciding to move pallets with an AGV rather than with conveyor?

Bernd: There are a variety of reasons why AGVs can be a better solution than conveyor. With an AGV system, there is much more flexibility. Once a conveyor system is in place, it is difficult to change or add to it. An AGV system, on the other hand, does not have this problem. Small adjustments can be made within a few minutes, sometimes even remotely.

Also, an AGV system is usually more cost-effective than pallet conveyor at lower throughputs. Pallet conveyors may make more sense once the number of transports exceeds that which is normal for an AGV. AGVs can, for example, be linked and connected to existing infrastructure or integrated into the AGV control system by means of the appropriate software or digital interfaces like an external transport system for pallets. Furthermore, AGVs can also use, an existing freight elevator for a floor change. A pallet conveyor system requires a separate lift to move pallets between floors.

3. Once a decision is made to dedicate a certain amount of floor space for the movement of pallets there are several options to choose from. Off the top of my head, I know that conveyor, rail-guided vehicles and transfer cars are the most common encountered fixed path pallet movement devices. What factors do you consider when it comes to recommending one of these devices over another? Are there critical criteria or numbers to consider?

Emanuel: There are several options to match a company’s desired function and requirements. In addition, Stoecklin’s experienced sales engineers who analyze the process a company is looking to automate and then, based on a thorough analysis, offer an optimized solution. For instance, to streamline the design and development process, Stoecklin created “Element-specific” documentation, and a ‘Master-PPT’ that accumulates all “Element-specific” documents.

The deciding factors for all pallet transportation projects are requirements and functions, as in what is the purpose of the process and where in the plant does this process happens, and plant performance, which includes system and element performance. Plant safety is always a critical factor as well.
The ultimate system design is reviewed by the responsible team, who are going over all the specifications. This team determines if the system meets the company’s requirements and then approves it to present to the client. There are many ways that companies can increase efficiency and reduce costs by automating processes. However, it is important to remember that every company has a unique set of requirements and procedures. Conveyor systems maybe just right for company A, whereas AGVs check off all the requirements company B has for an automated solution.

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Emanuel Rippstein, Product Manager for Conveyor Systems, and Bernd Krebs, Product Manager for AGVs