Kaufman Engineered Systems' full-layer K5 bulk PET plastic bottle palletizing system features three FANUC robots, a multilane infeed conveyor, and dynamic dunnage.

A FANUC R1000-80H robot integrated with a custom eight-lane bottle end-of-arm tool transfers rows of bottles on the Kaufman-supplied mat-top conveyor to assemble full layers of bottles. A FANUC M410/500 robot picks full layers of bottles presented by the layer forming mat-top conveyor and palletizes unit loads up to 9 layers high. The number of layers to be palletized is selectable via the AB PanelView HMI. A FANUC M410/140H robot works in unison with the M410/500 robot to pick and place pallets, tier sheets, and top frames during the unit load build process. Sheets are placed on the pallet between layers, and a top frame is placed on the top of the load, completing the unit load build sequence. Tier sheets, top frames, and pallet stacks are stored in the system on a Kaufman-supplied single lane infeed conveyor, where 3 zones are designed to hold the dunnage. Finished loads exit the palletizing location to a Signode automatic compression strapping unit. Here, finished loads are secured prior to being sent out by the Kaufman automatic stretch wrap system.