loading automation: a complete guide to pallet loading

Traditionally, businesses use pallet jacks or forklifts to load pallet onto trucks, also known as manual loading; however, pallet loading this way has limitations:

• Forklift usage is manual
• The pallets must undergo manual checks
• Securing the pallets is also manual.

All this manual work creates certain issues:

• Trailer damage: forklift usage damages trailers;
• Labour-intensity: the manual nature of pallet loading forces workers to exert themselves to keep on schedule. The work is physically demanding;
• Inconsistent loading patterns: loading pallets manually makes it harder to observe consistent loading patterns;
• Health and safety hazards: unfortunately, loading manually with forklifts poses myriad risks, including collisions, overturning vehicles and falling cargo, which can cause injury and even death;

standard unmodified trailers vs modified automated trailers

Automated loading solutions come in two different types, depending on the operator’s needs:

• Automated Trailer Loading Solutions (ATLS): For automatically loading and unloading the same trailer, such as those required in shuttle-run operations, the trailer floor can be modified by installing the automated loading system into it. This enables safe 2 minute loading and unloading. 
• Unmodified Trailers Loading Solutions: suit third-party logistics (3PLs) providers because they give the 3PLs flexibility to work with pallets of different sizes. Large companies that conduct their own logistics may prefer a modified trailer because they’ll own their fleet and work regularly with the same-sized pallets.

LoadMatic

The LoadMatic is a fully automated loading system for standard nonmodified trucks and trailers. The system handles palletised and non-palletised goods and suits the following industries:

• Petrochemical: where it can make loading safer, reduce labour and handling costs and replace machinery, and has helped a chemical-based business in Finland;
• Mining: where it minimises employee contact with hazardous materials and heavy machinery, lowers operation costs and reduce handling errors;
• FMGCs: where it can reduce product damage, labour costs and loading times, and boost throughput and efficiency when loading pallets or non-palletised goods;
• Beverage: where it reduces operational costs and turnaround times, increases safety and lowers the risk of product damage.

Moving Floor

The Moving Floor Conveyor is a versatile, heavy-duty loading solution that can handle palletised goods and bulky, non-palletised ones.

• Flooring manufacturer Bjelin, which produces 200 pallets a day of various-sized palletised goods, has cut loading cycles significantly from potentially three hours to minutes.
• The Moving Floor Conveyor also supports food and drinks companies such as Bimbo and Diageo, and packing industry company Tetra Pak.

Slipchain

Slipchain is another heavy-duty automated loading solution for pallet loading.

• Packaging industry company MM Deeside Ltd turned to the Slipchain to load finished goods from its factory onto trailers and unload them at a nearby warehouse. By doing so, the company has reduced its risk of damaged pallets and goods, increased efficiency, made substantial cost savings and created a safer loading area.
• By implementing the Slipchain automated loading system, Ypê streamlined the transfer of finished goods between its production facility and warehouse. The solution reduced the risk of pallet and product damage, improved loading efficiency, delivered significant operational cost savings and helped create a safer working environment by minimising manual handling and forklift movements.