Last month we provided an automation audit tool to provide a fresh perspective on your automation opportunities. In this article, we look at some of the new and emerging technologies that just might play a role in the future of your company.
Some of them, like robotics, machine vision inspection, IoT and board scanning and optimization are already making inroads. The future of other technologies for the pallet sector, such as autonomous vehicles and 3D printing, is more speculative. Here are some opportunities to consider.
Machine Vision for Pallet Inspection
Vision inspection systems (sometimes referred to as machine vision systems) have provided consistently accurate, image-based inspection for a variety of industrial and manufacturing applications for years. More recently, there have been expressions of interest from pallet recyclers, end-of-line inspection for new pallets, as well as by pallet users – especially those with automated pallet handling and storage systems.
CHEP has popularized automated digital inspection (ADI) technology by installing this equipment in dozens and dozens of service centers in both North America and Europe. The CHEP ADI utilizes high-definition cameras and lasers. It checks the dimensions of pallets as well as looking for structural damage.
In the June issue of Pallet Enterprise, we covered SmartReturn, a Nordic pallet company that is installing the PalletInspector. The PalletInspector is a vision-based inspection system offered by IVISYS, a Sweden-based automated inspection system provider that has been serving the industry for over 20 years. Aside from the benefits of automation, SmartReturn is looking at the PalletInspector to build greater trust with customers by providing an honest and accurate reporting of inbound pallet quality while being able to generate data insight on a very granular level.
According to Carl Brandt, IVISYS sales executive, the PalletInspector offers a throughput of 200-300 pallets per hour, with 500 per hour “nearing the limit of our current technology,” he said. The company is working to significantly increase throughput. The system detects geometrical defects, discoloration, and logos across multiple pallet types (including GMA) and sizes.”
The number of benefits to machine vision inspection compared to manual/mechanical inspection – higher throughput, smaller physical footprint, simplified commissioning, reduced maintenance needs while being able to inspect all aspects of the pallet with significantly higher accuracy.
“I think one key thing in this, which most are unaware of as an opportunity, is the data retention capabilities,” Brandt said. “So long as there’s traceability of the pallet, a recycling/pallet pool could get deep insights into how each customer impacts pallet quality.
“Questions like – what component is most worn with client X – can be answered with ease,” he continued. “We also see a possibility for large, automated warehouse operations to set up charge-back systems where if a supplier sends a pallet not conforming to standards, an invoice will be triggered.”
The company says that the PalletInspector is generating considerable interest from pallet users. “I think that the major driver for this is the automation of production, conveyor, warehouses and palletizing lines. With these types of advancements, defective pallets become a real nuisance as they can jam conveyors and automated handling equipment, posing an EHS (environmental, health and safety) concern to operators in production lines and warehouses.”
There has also been interest from new pallet manufacturers for quality control at the end of the manufacturing line for spotting protruding nails – top or bottom. The company has several installations in Europe addressing this need.
Like the CHEP system, the PalletInspector is centered around machine vision, utilizing several camera technologies and lasers to determine the pallet quality. What separates the PalletInspector, the company stated, is the widespread use of artificial intelligence (AI) complementing the cameras and lasers. The AI helps in detecting and measuring defects and logos or stamps that are challenging to measure with only cameras and lasers alone.
Board Scanning and Optimization
While scanning and optimization solutions have become increasingly popular in sawmills, one exciting breakthrough has been the deployment of this technology for the optimization of high-speed deck board processing. The need for such a solution has never been greater as the pallet industry faces supply challenges for both lumber and labor.
Alliance Automation’s Urban Sawmill is designed to handle the labor-intensive process of sorting and trimming random, odd-sized boards, which is a huge challenge for any pallet disassembly operation. The system scans random deck and bottom boards for length, width, and thickness. Boards are then optimized and trimmed to the desired finished length. Individual sort bins capture the reclassified lumber of predetermined dimensions.
Even more recently PRS Group has introduced its new Auto-Max optimized trim saw line. The Auto-Max can feed, scan, optimize, prioritize output end products, cut, and sort multiple lengths/widths/thickness categories – accurately and consistently at a rate of 3,000 boards per hour.
“Higher costs across the board for materials and labor are a new reality,” Jeff Williams, President of PRS, recently told Pallet Enterprise. “I don’t see that headed in a favorable direction anytime soon. This new dynamic increases the need to extract as much value as possible from these inputs and leveraging the benefits of automation in material processing can achieve that and more.”
Robotics
Robotics have been used in Europe for many years, where they are visible in new pallet manufacturing activities such as placing pallet components or mats, stacking, and in other applications, such as precision drilling handling awkwardly sized panels in wood packaging operations. Robots have made fewer inroads in North America, although that situation is posed to change. Pallet Alliance’s Robotic Dismantler has gained acceptance in the U.S. market, helping to eliminate the physically demanding work of running pallets through a bandsaw dismantler. The Robotic Dismantler has been successful in helping companies increase board recovery, reducing backlogs of unprocessed pallets, and making work easier.
The use of robotics for repair has also been adopted by CHEP. At its September 2021 investor briefing, it reported having 42 Klippa robotic board removal systems operating at its North American service centers. It seems likely that more domestic pallet companies in both new and recycled sectors will be giving robots a closer look as installations increase.
Industry 4.0
Industry 4.0 embraces several advanced technologies such as Big Data and Analytics, the Cloud, Augmented Reality, Artificial Intelligence and the Industrial Internet of Things (IIoT). Generally speaking, it refers to the application of digital technologies to solve manufacturing challenges.
Increasingly, pallet manufacturing and sawmilling systems include remote monitoring and diagnostics capabilities, allowing plant managers to track production and performance off-site. Additionally, equipment issues can be diagnosed remotely by vendor technicians.
One recent example of digital technology solving a problem is the SAWSENSE system from Williams and White. Temperature fluctuations and differences between the eye and the rim of a saw cause a deformation that can reduce the life of the saw. Sensors in the saw guide constantly monitor temperature automatically and will send signals out through IIoT to the saw guide lube system to apply the appropriate amount of lubrication. As a result, saw and mill throughput can be improved, while oil usage is reduced by as much as 40%. Less oil translates into less corrosion and pooling, as well as higher chip quality.
Autonomous Forklifts
While autonomous material handling robots have become household knowledge thanks to Amazon, it is still early days for autonomous forklifts. Nonetheless, they are on the horizon. Initial deployments have been indoors in relatively clean, predictable environments. Yale, for example, has sold more than 400 autonomous reach trucks. Autonomous vehicles are also being explored for the loading and unloading of trailers for example. Technological advances continue and are broadening the potential for autonomous lift trucks in more challenging workplaces such as lumber products facilities.
In autumn 2021, two of Sweden’s largest forestry companies will be conducting a feasibility study to investigate the opportunity for autonomous lift trucks in sawmills. A key desired outcome is improved worker safety. If the feasibility study is successful, a pilot project will be planned to test the solution in live production with the aim of putting autonomous vehicles into operation in the future.
“At Holmen, we are continuously exploring new technology and innovative solutions in order to develop our activities,” commented Magnus Malmström, site manager at Holmen’s sawmill in Iggesund. “To ensure the safety of our employees is obviously a top priority for us, and we would therefore like to explore the potential of autonomous vehicles.”
3D Printing
It would be great to be able to print pallets as needed, wouldn’t it? It is true that 3D printing continues to gain acceptance and is now being used in mass production applications. Currently this technology is used for value-added parts and products. 3D printing from wood is now possible and being commercialized by a company called Forust. It offers the 3D printing of complex wood parts or products.
“When considering whether 3D printing makes sense for pallets or pallet components,” offered Andrew Jeffery, CEO, “the answer really depends on the price of wood. Wooden pallets can be used only a few times before they break. With 3D printing, one could make an improved pallet and also make it with extra features that might be helpful to support items that are being shipped.” In other words, it might be applicable in highly specialized use cases.
While some automation technologies don’t necessarily make sense for pallets, industry at large’s shift to automation is ongoing. And it is important for the pallet industry to continue dreaming and watching for future technology transfer opportunities.
