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Palletizer / Depalletizer Upgrade Catalog

Upgrade your existing packaging equipmentUpgrading your existing packaging equipment can be a cost-effective alternative to replacing some units or systems. Our experienced team will audit your equipment and determine the feasibility and benefits of upgrading your system to improve its effectiveness.

Why should I upgrade?There are multiple reasons for needing to upgrade your existing packaging equipment from a need for increase packaging volumes, new industry requirement that require a change to your existing products, safety concerns or old inefficient equipment to rebuild. We have upgrades available for our legacy brands including but not limited to: Control Systems, Safety Upgrades, Change Parts, End-of-Arm Tooling, Certified Pre-owned Tray and Bliss Formers, Top and Tier Sheet Dispensers, Pallet Dispensers, Packaging Line Relocation, Line Layout Changes, Pattern Changes, Obsolete Components, Complete rebuild of machine, Palletizer and Depalletizer Upgrades, Updating earlier models with latest innovation advancements.

Electrical Upgrades . . . . . . . . . . . . . . . 3, 4Allen-Bradley 1791-I/O Blocks - Discontinued .3Allen-Bradley 1794-ASB module - Discontinued 3Allen-Bradley PanelView Plus Touch Screen . . . . 3Allen-Bradley PLC . . . . . . . . . . . . . . . . . . . . . . . . . . 3Allen-Bradley VFD . . . . . . . . . . . . . . . . . . . . . . . . . . 3Hydraulic to Electric . . . . . . . . . . . . . . . . . . . . . . . . 3Industrial Communication Router . . . . . . . . . . . . .4Main Control Enclosure Replacement . . . . . . . . .4Safety Light Curtain . . . . . . . . . . . . . . . . . . . . . . . . .4

Global Markets / Manufacturing . . . . . 11Global Manufacturing . . . . . . . . . . . . . . . . . . . .11Global Markets . . . . . . . . . . . . . . . . . . . . . . . . . .11

Mechanical Upgrades . .4, 5, 6, 7, 8, 9, 10Depalletizers (Bulk) . . . . . . . . . . . . . . . . . . 4, 5, 6

3-Position Sweep . . . . . . . . . . . . . . . . . . . . . . . . . . .4Destrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Dunnage Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Dunnage Bins - Offline & Inline Overhead . . . . . 5Height Paddle Detection . . . . . . . . . . . . . . . . . . . . 5Lift Hoist Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Manual Strap Chopper . . . . . . . . . . . . . . . . . . . . . . 5Robotic Unwrapper . . . . . . . . . . . . . . . . . . . . . . . . . 5Sweep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Sweep Pivoting Pusher . . . . . . . . . . . . . . . . . . . . . .6Top Sheet Hold Down . . . . . . . . . . . . . . . . . . . . . . .6

Pallet Changeover . . . . . . . . . . . . . . . . . . . . . . . 6Auto Adjust Empty Pallet Guides . . . . . . . . . . . . . .6Main Lift Auto Adjust Pallet Guides . . . . . . . . . . . .6Main Lift Pallet Stops . . . . . . . . . . . . . . . . . . . . . . . .6

Pallet Handling . . . . . . . . . . . . . . . . . . . . . . . . 6, 7Pallet Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Pallet Stacker/Unstacker . . . . . . . . . . . . . . . . . . . . . 7

Palletizers (Bulk Can) . . . . . . . . . . . . . . . . . . 7, 8Airliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Automated Top Frame Handling . . . . . . . . . . . . . . 7Dedicated Stagger Head . . . . . . . . . . . . . . . . . . . . . 7Empty Pallet Magazine . . . . . . . . . . . . . . . . . . . . . . 7Servo Pallet Transfer . . . . . . . . . . . . . . . . . . . . . . . . 7Servo Positioner and Stabilizer . . . . . . . . . . . . . . .8Top Frame Handling . . . . . . . . . . . . . . . . . . . . . . . .8

Palletizers (Case) . . . . . . . . . . . . . . . . . . . . . . 8, 9Adjustable Divider Lanes . . . . . . . . . . . . . . . . . . . . .8Automatic Divider Adjust . . . . . . . . . . . . . . . . . . . .8Beaded Rail Case Guides . . . . . . . . . . . . . . . . . . . .8Center-Drive with Nose Over Transition . . . . . . .8Floor Level Dirt Sheet Inserter . . . . . . . . . . . . . . . .9Maximizer Dual Bridge Turners . . . . . . . . . . . . . . .9Pattern Addition/Change . . . . . . . . . . . . . . . . . . . .9Skate Roller Case Transfer . . . . . . . . . . . . . . . . . . .9Upper Lift Extended Pusher . . . . . . . . . . . . . . . . . .9

Palletizers (RoboMax) . . . . . . . . . . . . . . . . . . . . 9Robotic Case Turning and Pattern Forming . . . .9

Product Changeover . . . . . . . . . . . . . . . . . . . . 10Adjustable Case Palletizer Infeed . . . . . . . . . . . . 10Digital Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Safety Guarding for Empty Pallet System . . . . . . 10Safety Upgrade for Pallet Discharge Tunnel . . . 10

Sheet Handling . . . . . . . . . . . . . . . . . . . . . . . . . 10Autoserter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Indexing Separator . . . . . . . . . . . . . . . . . . . . . . . . 10

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IndexIndex

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Electrical Upgrades

Allen-Bradley 1791-I/O Blocks - DiscontinuedWith the discontinuation of the block, pictured below, we recommend completing a controls upgrade, which will replace outdated components with up-to-date ones.

Allen-Bradley 1794-ASB module - DiscontinuedWith the discontinuation of the below module, we recommend completing a controls upgrade, which will replace outdated components with up-to-date ones.

Allen-Bradley PanelView Plus Touch ScreenThis upgrade will replace obsolete touch screens, pushbutton type control panel, or data liners with a touch screen type. An operator can choose between systems screen, run screen, product sheet screen and a diagnostic history screen which allows operator communication with the PLC and eliminates the need for a laptop computer to make adjustments.

Allen-Bradley PLCIf you have remote I/O in your existing PLC and the adapters fail, purchasing used ones from the internet may prove expensive, unreliable, or non-functional. We recommend our upgrade PLC Package which includes the rack, processor, power supply, input modules, output modules, Ethernet module, Ethernet hub and complete program conversions that are used in our current machines.

Allen-Bradley VFDNew drives operate faster and perform better than old, obsolete drives. They provide “safe torque off” function as an option, if required, and have better and more programming options. They also offer ethernet IP communication, if required.

Electrical Upgrades 3

Hydraulic to ElectricCan replace a single hydraulic application or an entire machine’s hydraulic system. Reduces or eliminates potential hydraulic leaks/spills.

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4 Electrical Upgrades / Mechanical Upgrades - Depalletizers (Bulk)

Main Control Enclosure ReplacementThe new panel comes with a PLC. This upgrade will include a fusible disconnect, panels, overload protection, circuit breaker, motor starters, contact blocks, terminal strips, power supply, relays, wire ways, miscellaneous components, and a new documentation package with new electrical schematic.

Industrial Communication RouterCombines a modem and an IP router for both serial and Ethernet PLC protocols allowing a qualified person to remotely observe and make changes to the PLC program.

Safety Light CurtainThe one-way safety light curtain can be fit onto any entrance or exit point of a palletizer or depalletizer, and can be a standalone upgrade or as part of a complete control package and Category 3 safety upgrade.

DestrapperAutomates the removal of the straps from your empty container pallet. The Destrapper cuts the straps and automatically disposes of them into a large container. It will integrate into an existing depalletizer and comes with its own control package.

Dunnage BinUpgrades existing dunnage bins with pneumatic operated doors. Bombay doors can also be added to better handle a group of sheets or top frames.

Manual

Bombay DoorsPneuma�cally

OperatedBin Doors

Mechanical Upgrades

Depalletizers (Bulk)

3-Position SweepThis sweep upgrade allows for separate slip sheets, and top frame positioning. The top frame and top sheet can be picked simultaneously with this upgrade.

Top frame deposit posi�on

3-posi�on Sweep

Slip sheet deposit posi�on

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Mechanical Upgrades - Depalletizers (Bulk) 5

SweepImprove speed and tier sweeping ability while improving overall efficiency. Upgrade can include new belt drive package with shaft-mounted SEW gearmotor. New sensors for position control are included. New sheet pick-up and top frame pick-up. 2-position or 3-position sweeps. Available in linear shaft or high-speed roller wheel configurations.

Robotic UnwrapperOur Unwrapper integrates into an existing depalletizing line and removes the stretch wrap from the pallet. It comes complete with safety guarding and control interface.

Manual Strap ChopperWhen an operator has manually destrapped a pallet., the manual strap chopper will chop up straps and put them into a large container.

Height Paddle DetectionDo you have a need for multiple container heights. With this upgrade an operator selects height settings (infinite size adjustment within range). It may include electrical upgrade with a PanelView graphic terminal on some models.

Depalletizers (Bulk)

Dunnage Bins - Offline & Inline OverheadFor additional sheet storage and top frame storage, this upgrade offers high-level, mid-level, and low-level access. Automatic discharging of loads is also available.

Top frame bin Slipsheet bin

Lift Hoist DriveThis upgrade, for ACME/Simplimatic 400D Bulk Depalletizers, replaces the expensive, obsolete, and long lead 2-speed lift motor and reversing starter with a standard AC motor and new Allen-Bradley frequency drive for added speed and control. Optional encoder control is available.

Depalletizers (Bulk)

Sweep Pivoting PusherThe sweep pusher can be upgraded with a pivoting pusher and sensors that is used to detect pushing jams, and protect the machine before damage occurs.

Top Sheet Hold DownThis mechanism will secure the sheet on top of the pallet, during the last sweep cycle, and is recommended for the Wyard BDA-3200.

Last sheet hold down

Sheet clamps

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# Product Category6 Mechanical Upgrades - Depalletizers (Bulk) / Pallet Changeover / Handling

Main Lift Pallet StopsAutomatically adjustable for various positions, and can be controlled through the HMI (may require HMI upgrade).

Main Lift Auto Adjust Pallet GuidesIf running multiple pallet sizes, the lift pallet guides can be upgraded to tool-less manual or automatic changeover.

Pallet Changeover

Auto Adjust Empty Pallet GuidesReplaces slots and slides for repeated empty pallet size changeover. Changeover can be done with a press of a button on the HMI screen, simplifying changeover - especially multiple positions.

Pallet Handling

Pallet ConveyorImproved rugged design and construction. Deck plate design provides a clean look, allowing no product build-up. All other pallet conveyor can be upgraded, such as turntables, right-angle transfers, straight, and curved sections.

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Product Category #Mechanical Upgrades - Pallet Handling / Palletizers (Bulk Can) 7

Pallet Handling

Pallet Stacker/UnstackerUpdated pallet stacker/unstacker design improves speed and stacking ability. Minimum floor space is required with increased efficiency.

Palletizers (Bulk Can)

AirlinerProduces void-free patterns. High-pressure zones allow cans to effectively meter into various lanes. This reduces or eliminates the need for an operator at the top of the machine. Includes removable deck.

Automated Top Frame HandlingTop frame dispenser automatically places the top frames onto the pallet outside of the hoist. It reduces pallet changeover time, when compared to manual operation.

Empty Pallet MagazineThe upgrade will lift a single pallet, instead of an entire stack - eliminating hazardous loads overhead. Includes guarding and safety light curtain for added safety.

Dedicated Stagger HeadAll machined parts are on exact centerlines as pattern and can diameter. Provides a smoother and faster operation than older stagger heads.

Servo Pallet TransferPrecise movement of the pallet with controlled start and stop with servo. Replaces the old, dual-cylinder style pusher with a single-cylinder linked pusher or servo-actuated pusher. The servo upgrade is faster than the single cylinder upgrade. Includes robust framework.

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8 Mechanical Upgrades - Palletizers (Bulk Can / Case)

Palletizers (Bulk Can)

Servo Positioner and StabilizerEfficiently stabilizes and handles tall cans. Increases the layer speed of 7-10 layers per minute, depending upon can height.

Top Frame HandlingThe head and lifting area are upgraded - replacing the old design (cam followers riding on a tube) with a new design featuring a profiled rail and bearing. The new head is made of aluminum extrusion.

Center-Drive with Nose Over TransitionAssists in transferring cases during pattern forming, and as a result, filler rollers are eliminated. Prevents narrow cases from tipping at transfers, and smooths product travel over transfer points.

Beaded Rail Case GuidesAssists in transferring cases during pattern forming. Reduces turned cases, and the risk of potential package damage.

Beaded Rail Case Guide

Palletizers (Case)

Adjustable Divider LanesUp to nine lanes total, of which six lanes can be adjusted. The adjustable divider lanes put the cases where the turners will be positioned.

Automatic Divider AdjustUpon selecting the pattern from the HMI, the six adjustable lanes will be automatically adjusted. This eliminates risk of operator inputting incorrect settings, or forgetting to change settings. This upgrade applies to the Maximizer palletizer.

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Mechanical Upgrades - Palletizers (Case / Robomax) 9

Maximizer Dual Bridge TurnersReplaces outer turners for faster, more-efficient, turning of product. Features hand-crank adjustment with dial indicators, low-pressure shock-absorbing turners. Allows turners to be put where the cases need to be.

Pattern Addition/ChangeAdd a new pattern or change an existing pattern. This upgrade is dependent upon the pattern addition/change needed, and may require other upgrades to complete.

Palletizers (Case)

Floor Level Dirt Sheet InserterAdds bottom sheets to pallets, and can also replace an existing bottom sheeter.

Skate Roller Case TransferImproves efficiency of product movement across conveyors, and improves case transition during pattern forming.

Upper Lift Extended PusherThis upgrade, for the Maximizer palletizer, provides additional area to allow for greater flexibility in pattern configurations.

Palletizers (RoboMax)

Case Turning & Pattern FormingRobots replace divider and bump turners, providing gentler handling of product, reducing maintenance cost - fewer wear parts. Robots accurately position and/or turn each case, tray or bundle into the selected layer pattern. Configurable to allow for virtually unlimited product and pattern combinations.

Indexing SeparatorAllows for separating of layer pads on automatic machines. Increases the reliability of the Autoserter, while eliminating double-sheet picks, especially with new, sheared stacks of sheets.

Sheet Handling

AutoserterServo-driven, chain and spring timing. Arm is extruded for faster handling of sheets. Sheets are handled with suction cups. The Autoserter works especially well when used in conjunction with the Indexing Separator.

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10 Mechanical Upgrades - Product Changover / Safety / Sheet Handling

Safety

Safety Guarding for Empty Pallet SystemProvides the greatest personal protection from pinch points and bodily injuries.

Safety Upgrade for Pallet Discharge TunnelIncludes extended guarding, plus a one-way light curtain. It can be part of a complete Category 3 safety control upgrade, or a stand-alone upgrade.

Product Changeover

Adjustable Case Palletizer InfeedImproves infeed changeover for cases and keeps cases on machine centerline after adjustment. Optional offerings include: Case hold-down that can prevent case rolling or tip-overs, and case pairing for improved speed of small case handling.

Digital CounterCan be added to your changeover points - eliminating start-up delays due to adjustment accuracy.

Plumtree Farm Industrial EstateBircotes, Doncaster

South Yorkshire DN11 8EW ENGLANDt. +44 (0) 1302 711056

1305 Lakeview DriveRomeoville, IL 60446 USAt. +1 (630) 759-6800

Palletizing | Depalletizing Feeders & Placers | Cartoning Case Packing | Bliss, Tray &

Case Erecting | Conveyance & Controls | Can Handling | Can End

Handling | Robotic Solutions Systems Integration

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Labeling | Sleeving | Converting

accraply.com

Rigid Form-Fill-Seal | Rigid Fill-SealComplete Line Integration

synerlink.com

Vertical Form-Fill-Seal | Horizontal Form-Fill-Seal | Pre-made Bag Filling Bag Converting | Product Feeding &

Weighing | Bag Conveyance & Palletizing

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Filling | Capping | Seaming Labeling | Centrifuge

psangelus.com

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FILLING, SEALING, SEAMING & CAPPING

LABELING & SLEEVING

FLEXIBLE PACKAGING

END OF LINE & SYSTEMS INTEGRATION

Product Category Page #

• Container Manufacturing• Food• Beverage• Beer• Dairy

• Wine and Spirits• Home and Personal Care• Industrial and Automotive• Paper• Bakery and Confectionary

• Romeoville, IL USA• Doncaster, S. Yorkshire UK• Fergus Falls, MN USA• Loveland, CO USA

• Lynchburg, VA USA• Minneapolis, MN USA• Reedley, CA USA

Global MarketsBW Integrated Systems provides diverse solutions to a variety of market segments around the Globe:

Global ManufacturingBW Integrated Systems has seven global manufacturing facilities.

Contact one of our representatives today to set-up an appointment to review your current needs for any of the above brands along with ACME and Simplimatic Wyard to name additional.

Global Markets / Manufacturing 11