The Advantages and Disadvantages of Not Using Compressed Air in a Palletiser

September 2024

Palletisers are essential machines in modern manufacturing and distribution environments, playing a crucial role in stacking products onto pallets for efficient storage and transport. Traditionally, many palletisers have relied on compressed air systems for various functions, including actuating grippers, moving products, and controlling machine components. However, with technological advancements, there has been a growing trend toward designing palletisers that do not use compressed air. This shift can significantly affect operational efficiency, costs, and maintenance requirements. This article explores the advantages and disadvantages of not using compressed air in a palletiser.

Advantages of Not Using Compressed Air in a Palletiser

Cost Savings

One of the most compelling reasons for eliminating compressed air in palletisers is the potential for significant cost savings. Compressed air systems are notoriously expensive due to the high energy consumption required to generate and maintain air pressure. Companies can reduce energy costs by opting for a palletiser that does not use compressed air, leading to lower overall operating expenses.

Improved Energy Efficiency

Palletisers that do not rely on compressed air are typically more energy-efficient. Compressed air systems often suffer from inefficiencies, including leaks and pressure drops, which result in wasted energy. In contrast, mechanical or electric systems used in non-compressed air palletisers are generally more efficient, translating to a smaller carbon footprint and enhanced sustainability for the operation.

Reduced Maintenance Requirements

Compressed air systems require regular maintenance to ensure proper functioning, including monitoring for leaks, checking pressure levels, and servicing compressors. This maintenance can be time-consuming and costly. By eliminating compressed air from the palletiser, companies can significantly reduce the complexity of their maintenance routines, lowering downtime and prolonging the lifespan of the equipment.

Enhanced Reliability and Precision

Mechanical and electric systems used in place of compressed air can offer greater reliability and precision in palletising operations. Compressed air can be unpredictable due to fluctuations in pressure and potential leaks, leading to inconsistent performance. On the other hand, electric motors and servo drives provide more consistent and precise control, improving the overall accuracy of the palletising process.

Quieter Operation

Compressed air systems can be noisy, contributing to a louder working environment that may require additional measures for noise control. Using electric or mechanical systems instead, palletisers can operate more quietly, creating a more pleasant and safer work environment for employees. There are, however, noise, noise-saving devices that can make pneumatic systems operate quieter, such as mufflers and silencers. Whilst they may reduce noise, they affect the operation of the tooling.

Disadvantages of Not Using Compressed Air in a Palletiser

Initial Investment Costs

The use of non-compressed air palletisers should offer long-term savings. The initial investment costs may be compatible if we consider that some compressed air pick-up heads may require bespoke, design hours and additional air pipework, which takes longer to build. Many manufacturers of “standard heads” are now offering integral vacuum generators, which also have vacuum sensing built in. For mechanical grippers, using servo drives to replace pneumatic actuators may be more expensive initially, but it often results in a much more compact designed unit. This also gives the advantage of making the gripper or end-of-arm tooling  (EOAT) lighter, allowing the palletiser to lift heavier loads. Whilst gripper heads with their vacuum generation or electric actuators can be used for many applications, they may not suit all,

Complexity in Retrofitting Existing Systems

For companies that already have palletisers with compressed air systems, retrofitting to a non-compressed air system can be complex and costly. It may involve significant modifications to the existing machinery or even entirely replacing the palletiser. This transition process can disrupt operations and require additional training for staff to handle the new systems. This may not be the case every time, as manufacturers are always offering new solutions that have been designed to ensure retrofitting challenges are minimised.

Potential Limitations in Speed and Flexibility

Compressed air systems are known for their ability to perform quick, repetitive motions, which can be advantageous in high-speed palletising applications. Some mechanical or electric systems may not match the speed or flexibility of compressed air systems, potentially leading to slower cycle times or reduced throughput in certain scenarios. Some of these concerns may be overcome by adding different sensors to improve response times.

Availability of Replacement Parts and Expertise

Compressed air technology is widely used across various industries, meaning that replacement parts and expertise are readily available. In contrast, the components used in non-compressed air palletisers may be less common, leading to longer lead times for parts. However, as more suppliers are beginning to offer more non-pneumatic solutions, the design of such tooling is becoming more modular, meaning components can then be easily replaced as opposed to replacing the complete unit.

Limited Applicability in Certain Environments

In some environments, the unique properties of compressed air – such as its ability to operate in explosive atmospheres or in the presence of dust and other contaminants – make it the preferred choice. Electric and mechanical systems may not be suitable or safe in these environments, limiting the applicability of non-compressed air palletisers in certain industries. These problems may be overcome by integrating ATEX rated equipment that is designed to work in such conditions. In-depth risk assessments need to be carried out to ensure the selected equipment is fit for purpose.

Conclusion

The decision to use or not use compressed air in a palletiser involves carefully weighing the advantages and disadvantages based on the specific needs and constraints of your operation. While eliminating compressed air can lead to significant cost savings, improved energy efficiency, and reduced maintenance, it may also present challenges related to initial investment, retrofitting, and potential limitations in performance.  As technology evolves, more “standard” offerings will become available, resulting in cost savings from both initial investments due to less time required for design and installation. As with any machine solution, there is never a one-size-fits-all size fits all, and it’s essential for the final solution to meet the task requirements now and in the future.

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For more information on how SP Automation & Robotics can help you choose the right palletising solution for your business, please contact us today. Are you ready to explore the possibilities of automation for your business? Contact SP Automation & Robotics to discuss how our bespoke automation solutions can transform your operations and set you on the path to success.