Pack Pattern Generator brings greater efficiency to the palletizing process in

With the development of its own pack pattern generator, SSI SCHAEFER positions itself at the forefront of the specialists of Automation-IT. The new software module "Schaefer Pack Pattern Generator (SPPG)" optimizes pallet build composition from the packing density of the inner pallet arrangement to the application of stability criteria in full or partly automated Case Picking Systems.

Edited: Andrea Ng, Regional Marketing SSI Schaefer Asia

Route optimization, loading space utilization and store layout optimized pallet building are the main components for cost saving and optimum service delivery. The diverse range of items now handled by retail and wholesale distribution centers presents immense challenges for multi-product palletizing. The computer-based calculation of all theoretically possible packing combinations of a store-optimized pallet alone would even today require an enormous amount of computing time which would be impractical. Furthermore, there is a multitude of restrictions for palletizing of different products, thus palletizing is normally carried out manually.

However, the processes in retail and wholesale trade logistics are becoming more and more automated. In the food industry, SSI SCHAEFER has developed the Schaefer Case Picking System (SCP) - an integrated system for fully-automatic, store-specific shipment compilation in the trade logistics, including fully-automatic palletizing. The physical pallet creation is done by the use of a packing robot using special gripper technology.

To fully automate optimized-palletizing that is in line with customer-specific requirements, SSI SCHAEFER has developed a special pack pattern generator named the Schaefer Pack Pattern Generator (SPPG). The SPPG is available as a software module for the Warehouse Management Systems (WMS) of the SSI Schaefer group. In interacting with the WMS, the generator enables the ‘impossible’ by calculating the optimal pallet building plan online in the shortest time and transfers it to the WMS. With this information, the WMS can initiate the operative processes smoothly.

In the process of optimizing storage space, the heterogeneous packages are arranged as densely as possible, depending on their geometry, and the pallets are built up as high as possible so that the pallet quantity can be minimized for every shipping order. Weight and ‘stackability’ of the packages needs to be considered and calculated exactly to be able to supply the goods undamaged to the stores. The allocation of goods by class is included in the planning so that the sorting efforts are also minimized upon arrival i.e. ‘store-friendly’ sequencing. Different requirements are needed for the packaging and product characteristics for different customers, sectors and markets. In the food sector specifically the beverage industry, special care is taken for the dry and deep-freeze assortment as well as the variety of non-standardized packages.

In the retail and wholesale trade distribution, packages vary widely in their dimensions, weights and stacking forms, and in their ‘stackability’ and load capacity as well as in goods type or in family groups. If possible, the articles in one family group should be arranged on one pallet. The most important aspects for the pack optimization are:

• Consideration of different load capacities and weights of the packages to fully utilize the permitted maxima of pallet height and weight.
• Positioning accuracy and stability of the packages during the entire pallet creation process. Every package has to stand steady and alone at its defined position without the help of additional auxiliary means.
• Implementation of different processing strategies to combine different goods and family groups.
• Maximum stability of the generated pallet to eliminate damage - not only on the conveyor system but also in the entire transport chain to the store.

Handling of non-standardized packages such as large packages with loose covers, light slip lids of display packages or returnable containers whose load capacity is different within the top load-bearing surface. For example, if products with a heavy package is put into its center, it would dip into the package below.

The objective of the SPPG-development is very simple: pallets that are automatically-generated and built must be better than the pallets which are manually built even by the best packers. However different product-related restrictions caused contradictory requirements in setting up a fully efficient system. The SSI SCHAEFER’s solution is to break down the entire process into different aspects of premises and restrictions. Customized solutions were defined for every aspect and integrated into the software. The combination of multiple strategies to address the above aspects made the entire process to solve the pack optimization problem.

Our first implementation of SPPG software module at one of the central warehouses of a large USA food wholesalers was proven to be very successful. The pallets planned by the SPPG are better than the manually-commissioned pallets with regards to the packing density, pallet count, as well as the production protection during the transport process.

In the SPPG, all necessary strategies are integrated in the fully-automatic palletizing so SSI SCHAEFER is able to supply a software module especially tailored to the individual requirement and processes of the customer. The priority of the optimization objects can, if necessary, be newly defined according to the customers’ needs. The refining systems engineering enables SPPG to calculate the optimum pallet design within the shortest time. After the system has performed calculations using the product and requirements data, the pallet can then proceed to build without any further calculations ad human interference. SPPG enables a truly heterogeneous range of products as well to undergo fully-automatic processing from order processing to palletizing. This reduces costs. The increased stability of the pallets also ensures less damage and in turn, higher customer satisfaction  Last but not least, the algorithms of the software module enable an optimal packing density and, therefore, the best possible utilization of available loading space. This reduces transport distance and costs and reduces pollution. Therefore the Schaefer Pack Pattern Generator forms an important component for further automation and efficiency of order processing in the trade.

Should you require any further information, please feel free to contact:

Central press office SSI Schaefer Germany:
Katharina Kunz, Fritz Schäfer GmbH
Phone +49/2735/70-395, E-Mail: katharina.kunz(at)ssi-schaefer.de

Press office SSI Schäfer Noell:
Desiree Kreisel, Marketing Automation
Phone +49/9334/979-541, E-Mail: desiree.kreisel(at)ssi-schaefer-noell.com