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Description of the Inline pallet changer “MASTER INVERTER with dedusting cabin”

The system guarantees productivity of 80 pallets per hour.

It is a bidirectional automatic line integrated with a Master Inverter pallet changer, which can be equipped with pallet magazines and machines for applying and removing stretch film with roller conveyors and chains for transporting the load on the pallet.

The pallet changing system involves the transfer of materials thanks to the Master Inverter pallet changer, able to change the pallet from wood to plastic/aluminum with a bidirectional movement towards production and vice versa. The Master Inverter in-line pallet changer allows the transfer of the product by pushing and holding on three sides. The Master Inverter device is inserted inside a dedusting cabin.

The pallet change operation is specially coordinated with the load dedusting process to prevent the transit of the wooden pallet from contaminating that of the plastic pallet.

In addition, this logistics line provides the dedust of materials entering into the warehouse by an air sheet (installed on the frame of the Master Inverter). The unit consists of a dedusting cabin (which contains the pallet changer) equipped with interlocked doors and a unit for blowing and air purification. In addition, there’s the option of an integrated additional blowing system with compressed air nozzles or a film cutting machine positioned at the beginning of the line.

This logistics system guarantees a faster pallet change than the stand-alone machine thanks to the pallet warehouses that are equipped with conveyors for the collection and delivery of wooden and plastic pallets. The automatic pallet changer is equipped with an adaptive centering system with sonar measurement that allows the goods to be centered inside the new pallet while compensating for the difference in size of the two pallets (if they are different). The security of the system is guaranteed through the use of a perimeter of metal meshes and man photocells for access control.

How does the dedusting cabin work?

The cabin is made with stainless steel walls with a scotch Brite finish, equipped with ceiling lights for internal lighting. The operating principle of pulverization is based on the action of high-speed air jets filtered through a HEPA filter. The launch of the air jets comes from adjustable and nozzle diffusers, mounted on a C-frame secured to the Master inverter. The recirculated air, before being filtered by the HEPA filter, passes through n. 2 prefilters G4. The maintenance of the prefilters is foreseen inside the cabin, through removable frames. A high-pressure electric fan allows the recirculation of the air and the expulsion of 10% of the same, after filtration in order to keep the interior at negative pressure. The HEPA filter is positioned in the upper external part of the cabin. The clogging control of the HEPA filter is managed by a MAGNEHELIC differential pressure gauge (scale 0-500 la)

How does the pallet change operation take place?

Below we describe the logistics system phases needed to replace wooden pallet with a plastic pallet. Vice versa, operation can be managed via PLC with adequate programming.

1. The operator, equipped with a forklift, positions the wooden pallet with the product on the loading / unloading roller conveyor. The wooden pallet with the load crosses the muting safety barrier and is positioned on the roller conveyor.

2. The system conveys the wooden pallet with the load from the roller conveyor to the rotating table. The operator, thanks to the hydraulic fifth wheel placed under the rotary table, can change the orientation of the workstation from position to position.
   The operator can also adjust the height of the workstation thanks to a system of hydraulic cylinders positioned under the rotary table. In this way the operator is able to perform the manually removing of the film from the product.

3. Once the film removal operations have been completed, the wooden pallet with the load crosses the muting safety barrier and is conveyed by the system from the position rotary table to the roller conveyor.

4. The separation door equipped on the spraying booth opens and the wooden pallet with the load is conveyed inside the spraying booth on the roller / chain exchange conveyor.
   After closing the separation door, the spraying cycle takes place.

5. At the end of the spraying cycle, depending on the selected pallet, a plastic pallet is released from the pallet magazine or onto the catenary while the separation door positioned on the side of the spraying booth opens.

6. The plastic pallet passes through the separation door and is conveyed by the catenary inside the spray booth, onto the roller / chain exchange conveyor where it is aligned with the wooden pallet with the load stationed on the conveyor.

After closing the separation door, the pallet change cycle begins:

– The shutter low down and the Master Inverter pressers close in order to block the wooden pallet and the load.

– The conveyor is raised thanks to a hydraulic system in order to compensate for the difference in height between the wooden and plastic pallets.

– The Toppy Master Inverter transfers the load from the wooden pallet positioned on the conveyor to the plastic pallet positioned on the conveyor.

– The shutter is raised and the Toppy Master Inverter pressers open releasing the load on the plastic pallet while the conveyor is lowered.

7. The dedusting cabin’s door opens in order to let the plastic pallet be transported from the conveyor to the roller conveyor.
8. The separation door closes. The plastic pallet with the product crosses the muting safety barrier and is conveyed from the roller conveyor to the loading / unloading roller conveyor, waiting to be removed by an operator equipped with a forklift. At the same time, after the separation door is closed, the separation door positioned on the side of the pulverizing cabin opens, and the empty wooden pallet is transported by the roller / chain exchange conveyor to the catenary. Depending on the selected pallet, the empty wooden pallet is then stored inside the wooden pallet stacker or while the separation door closes.

SECURITY SYSTEM

The MEKKANO gate combines with the components for the EASY BARRIER perimeter protection overcoming the limits of welded framing.

Using the pre-painted elements and original connecting systems with screw fastening, it is possible to assemble gates of different width in a rapid and clean way, making them ready to be installed. With the same elements, the MEKKANO gate can be prepared in the right or left configuration, with outward or inward opening.

All the configurations of the gate can be obtained either for the version with the upper support or without it. The high strength of the connecting elements makes the structure as rigid as a classic welded frame.

What is your need?

1. FROM WOODEN PALLET TO PLASTIC PALLET: In many companies, there must be a separation between the goods reception area, where the shipping pallet generally made of woods are stopped, to the “white area” of the warehouse, where sanitized pallets (aluminum or plastic) are used. In our range of production there is also multiple dedusting cabins able to decontaminate the products and the air in order to maintain the certified environment.

2. SAVINGS AND AUTOMATIC: For companies with large numbers of pallets to handle, we usually recommend automatic solutions, able to perform with many pallets every hour. Our system reduces the number of operators required for the production process and therefore the cost of labor.

3. STANDARDIZATION OF THE INTERNAL PALLET and CENTERING PRODUCTS: Modern production processes increasingly need to standardize all pallets that move products during the production cycle and often also in warehouse, which are usually automated.
   Our pallet changers system can suit perfectly because they are able to handle heavy goods and / or fragile products whatever is the incoming pallet, replace it with a used one and center the product. It’s also possible to carry our automatic packaging operations.

4. SHIPPING with SLIP SHEET WITHOUT PALLET: It’s essential to save on the transport cost of the shipment of finished products. The pallet represents an important cost for those with a high flow of outgoing products. In addition, without the use of the pallet in the shipment, companies greatly increase the number of products that can be stowed. Our Inverter pallet changer placed at the end of the production process, are able to insert automatically a slipsheet under the load, which will be ready for shipment without the pallet. The pallet stackers will automatically stack all the pallets removed.

5.  SAFETY and WORK REDUCTION FOR OPERATORS: Our Pallet Inverter significantly increase safety within the process, as the manual work of operators is seriously reduced. Our pallet Inverter systems are very safe as they are equipped with advanced safety systems. The access to dangerous areas is controlled by doors with sensors, photocells or laser scanners in order to prevent dangerous cycles.

6.  PICKING & AGV: We offer a logistics line able to automate the composition of the load. The pallet management is automated with the AGV system, in order to facilitate the operator in the composition of the load.

7.  CLEANING, DEDUSTING AND SANITIZING: In the production range with our pallet inverter can be implemented a sanitization or dedusting system. We usually supply these systems to companies that need to separate the “white” area from the “grey”. Where necessary, there are inserted few particle counters in order to check the cleanliness and sanitization of the air before opening the doors. The main objective is to avoid that too high numbers of particles remain suspended in certified atmospheres of UNI EN ISO 14644-1 certified environments (Federal Standard 209D, 209E in the United States).