how operations managers can increase throughput with an automated pallet handling system

• How do Pallet Handling Systems Impact Throughput?
• How Automated Pallet Handling Systems Increase Throughput
• Common Bottlenecks in Pallet Handling (and How to Fix Them)
• The Role of Automated Loading in End-to-End Throughput
• Proven Success With Our Automated Loading Solutions
• Building a High-Throughput Pallet Handling Operation

• Automated pallet handling increases throughput by reducing manual handling.
• Conveyor systems create continuous pallet flow.
• Robotics and AGVs eliminate bottlenecks.
• AS/RS improves storage density and retrieval speed.
• Automated trailer loading removes one of the largest warehouse bottlenecks.
• Higher throughput lowers operating costs while improving safety.

Core components of a pallet handling system

Pallet handling systems feature some or all the following pieces of equipment:

• pallet conveyors, such as roller conveyors, chain conveyors or belt ones, or others;
• transfer units e.g. turntables, which operators manually rotate to avoid stretching across pallets for loading, and pallet lifts, which elevate pallets;
• palletisers, which stack products automatically into a single, stable load;
• depalletisers, which remove goods from pallets;
• automated storage/retrieval systems (AS/RSs), which put away goods and retrieve them from designated storage areas;
• stretch wrappers, which wrap stretch film around products placed on pallets;
• pallet magazines, a mechanical way of storing pallets until the business needs them.

Where throughput is won or lost

Eagle-eyed operators can increase throughput by identifying areas of (potential) loss or potential gain. Several points in a logistics pallet solution create scope for this:

• transition points, where pallets are transferred from one piece of equipment to another;
• queuing times, the times pallets spend waiting to be loaded for shipping;
• empty travel, which entails trucks conducting trips unloaded;
• system downtime, the time systems spend out of action and waiting for repairs.

How do you measure pallet handling throughput?

Increasing throughput starts with measuring the right performance indicators. Operations managers should assess the entire pallet journey, from production to trailer loading, to identify where delays occur and where automation can deliver the greatest improvements.

Common pallet handling throughput KPIs include:

• Pallets moved per hour (PPH): Measures how many pallets your operation processes during a typical hour.
• Trailer turnaround time: The total time required to load or unload a trailer from arrival to departure.
• Dock utilisation: Shows how efficiently loading bays are being used throughout the day.
• Labour hours per pallet: Helps identify opportunities to reduce manual handling through automation.
• Order fulfilment time: Tracks how quickly customer orders move from storage to dispatch.
• Downtime: Measures how much production time is lost due to equipment failures or maintenance.
• Product damage rate: Indicates how effectively pallets are handled throughout the operation.

Monitoring these KPIs provides a clear baseline for improvement and helps quantify the return on investment (ROI) of automated pallet handling systems.

Integrating robotics and automated guide vehicles (AGVs)/autonomous mobile robots (AMRs)

Automated pallet handling systems integrate robotics and AGVs and AMRs, which increases throughput by:

• operating around the clock instead of forcing businesses to rely on shift-based labour;
• removing bottlenecks;
• creating flexible routing, by using robots, instead of obliging operators to use fixed paths constantly.

High-density storage with AS/RS and shuttle systems

AS/RS and shuttle systems:

• increase storage capacity;
• boost retrieval so operators fulfil orders faster;
• reduce travel distance.

Identifying bottlenecks in pallet flow systems can bolster pallet handling efficiency. Below are some common bottlenecks in bulk pallet handling and how to fix them.

Too much dependency on forklift trucks

Pallet handling with forklifts is highly inefficient. It creates congestion and is inconsistent.

The solution: an automated conveyor system (or systems) and automated pallet transport to standardise handling and maintain pallet handling flow.

Poor system layout

Poor system layouts can cause walkways, forklift aisles and vehicle routes to intersect. This creates delays and makes pallet handling unsafe.

The solution: zone-based design to ensure tasks are performed in designated zones and create safer, smoother workflows.

Automated loading is crucial in accelerating end-to-end throughput.

Trailer loading is still a critical bottleneck for several reasons:

• often, it’s still manual;
• trailer loading slows down the flow of automated pallet handling systems;
• it creates a mismatch between warehouse efficiency and dispatch
• the loading bay contributes to warehouse congestion because finished goods often accumulate while waiting for trailers to be loaded, limiting the productivity of upstream automated systems.

How automated trailer loading systems increase throughput

Automated trailer loading systems (ATLSs) like ours lend throughput a huge boost. When you use one of our ATLSs, you can:

• cut loading times from hours to just minutes;
• eliminate forklift loading delays;
• make the entire loading process much safer and more consistent.

Real-world applications of automated pallet handling

Lots of different industries have capitalised on the benefits of material handling automation.

• Manufacturing: manufacturers produce goods in high volumes and use automated conveyor systems to keep pallet flow continuous and increase throughput.
• Warehousing and distribution: the warehousing and distribution industries are also making powerful uses of automated pallet handling equipment to fulfil orders quicker and cope with stock keeping unit (SKU) variability. Automated storage solutions, such as AS/RSs, and automated conveyor systems enhance workplace safety, reduce costs and increase efficiency.

Total cost vs long-term return on investment (ROI)

Automated pallet loading and unloading requires a sizeable upfront investment, but it also offers a large ROI in the form of:

• Labour savings
• Improved efficiency
• Improved safety
• Higher throughput
• Less cargo damage
• Reduced downtime.

When deciding whether to purchase automated pallet handing equipment, decision-makers must weigh up the cost of the equipment and maintenance versus the ROI.

Lifecycle support and maintenance

After installing an ATLS, it’s essential to look after it for long-lasting, top performance.

We support you with:

• modular systems that enable you to scale your operations;
• preventive maintenance to address issues early and ensure optimal performance;
• system upgrades so that your loading systems align with industry standards and remain up to date.

To increase throughput, operations managers must make pallet flow smooth, automate the process and control it. This means evaluating the whole pallet handling system, instead of focusing on one component. Automating pallet handling offers a competitive advantage by accelerating the process, streamlining it and making operations more scalable.

To invest in one of our ATLSs and enjoy these benefits, email us at hello@joloda.com or message us via our contact form. We’ll discuss your pallet handling process and analyse it to recommend the best pallet handling solution, then install it quickly so you can start increasing your throughput in no time.