More productivity. New load types. Different packaging requirements. When your business’s needs change, your automated, robotic palletizing system needs to change, too. Time itself might also prompt a revamp: though robots are durable and known to last for a decade or more, the average lifespan of a robotic palletizer is 8 years.

Whether you need a different configuration to support your business’s growth or want to avoid interruptions by getting ahead of problems that can occur with aging equipment, there are several ways to make that happen. You can:

  • Modify the equipment you have
  • Replace the robot—along with any other equipment at the end of its useful lifespan
  • Start from scratch and invest in a new system
  • Let us walk you through your options.

Modify, Replace, Buy New: Understanding Your Options

Robot Palletizing System Modification

Cost


Lowest

Lifespan Extension


Dependent on Modifications

Disruption


Low
Petrochemical facility palletizing system

A modification is the simplest, least disruptive, and lowest cost solution. You keep the majority of your existing equipment but add new components to meet your new business needs.

For younger systems that are functioning well, a modification may be the best way to meet the changing needs of your business. With how easily robotic palletizing systems can be reconfigured and reprogrammed, and with how compact they are, they offer a great deal of flexibility. When your needs change, your system can change, too. Whether you want to add new lines, free up staff to focus on more value-added tasks, or support new areas of growth, modifications allow you to meet these needs and extend the lifespan of your system. Common additions to existing systems include new end effectors, bag rollers, and bar code scanners.

Choosing to modify your existing palletizing system can offer these benefits:

  • New packaging or products run smoothly on your existing system
  • Meet the latest safety standards
  • Production line performs better than when it was first installed
  • Addresses gaps in your end-of-line system that you discovered after it was first installed
A modification might be your answer if you:
  • Recently introduced new packaging or products
  • Are looking for productivity gains
  • Need to meet new safety guidelines
  • Have a system that’s less than 8 years old, still in good shape, and meets your needs outside of one or two new requirements

Robot Replacements

Cost


Medium

Lifespan Extension


8+

Disruption


Medium
Industrial Robotic Palletizing System

A robotic replacement falls between a modification and a system overhaul in terms of complexity and cost. Like a modification, however, this option minimizes disruption. Robotic arms can be replaced outside of business hours, keeping your system running without interruption.

Robots are commonly replaced after 8+ years—although some Columbia/Okura customers are still using robots into their second decade!

Going with a robot replacement offers the following benefits:

  • Readily available OEM parts
  • The latest motors and parts, which are better equipped to handle dust and dirt due to how the robot is constructed
  • Technology upgrades, including enabling remote support from our service team
  • Compliance with the latest safety standards and requirements
A robot replacement might be your answer if:
  • You want improved speed and performance to achieve a faster palletizing rate, but your system otherwise meets your needs
  • Your current system is 10+ years old
  • Preventing downtime is important
  • Parts are hard to get for your existing system

New Palletizing End-of-Line Equipment

Cost


High

Lifespan Extension


8+

Disruption


High
Barrett Pet Food

This option means investing in entirely new equipment and upgrading your end-of-line system with the latest technology. Not surprisingly, it’s the option that’s most labor and cost intensive. That said, overhauls are inevitable at some point in the palletizer life cycle. Nothing lasts forever!

Opting for a completely new robotic palletizing system offers valuable benefits. In addition to all the benefits of the robot replacement option, a full system update offers the latest updates across your entire line. It also gives you a full system built for your latest packaging and products, rather than modifying an existing aging line to accommodate them. While modifications and replacements can extend the lifespan of your existing system, a new system buys you 8+ years of reliable functionality.

New equipment might be your answer if:
  • Significant modifications are needed to keep your aging system running
  • Components in your system have aged to the point that they can no longer support daily wear and tear; you experience frequent breakdowns and interruptions during the course of normal operations
  • Staying competitive requires improving your end-of-line  efficiency, reliability, safety, and complying with the latest standards

Other Considerations for a Smooth Update to Your End-of-Line Palletizing System

You’ve looked at cost, weighed the pros and cons of each choice, and made your decision. Congratulations! What else do you need to know?

Appoint a Project Manager

Changes to your end-of-line system require planning to ensure your day-to-day operations continue with little to no disruption and your updates can come online with minimal disruptions or downtime.

For this reason, we advise that you have an in-house Project Manager to assist in:

  • Scheduling
  • Ensuring one point of contact for clear communication with your chosen integration provider
  • Working with your integration provider to outline the system’s needs
Train Employees

New components, a new robot, or an entirely new system—either way, training is a must. Columbia/Okura offers training for operators at our facility prior to the system shipping.  We can also conduct training for additional operators or new operators at your facility.

Replacing-Dirty-Jobs

Reach your business goals with the experts

Deciding between a retrofit, a rebuild, or new equipment for your end-of-line packaging machinery will depend on your specific needs and long-term goals. Determining your priority, whether it’s budget, longevity, or minimized downtime, will help you make a strong decision for the future of your operations.

If you have questions about what kinds of components are available to modify your end-of-line equipment or what kinds of enhancements you could experience with an upgraded robot arm or new system, please contact us. Our experienced engineers and support team can explain how enhancing your system can gain efficiencies and improve throughput—improving your business’s bottom line for years to come.