Tier Sheet System for Spouted Container Palletization
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Solution Overview
Problem
The existing methods for palletizing containers with extended portions or spouts are labor-intensive and inefficient, as they often require manual reassembly of damaged cases, and universal cases do not optimize space usage, leading to reduced packing density and increased costs.
Innovation Solution
A system using tier sheets with a top portion and projections to separate layers of spouted containers on a pallet, which are designed to accommodate various sizes and orientations, providing a safe channel for spouts and distributing weight evenly, thus allowing for efficient bulk handling and palletization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If case or box packing is used for spouted containers, then protection and organization are provided, but cost and labor intensity increase due to re-erection of damaged cases
Solution Approach 1:
The invention extracts the protective function from reusable cases/boxes and transfers it to disposable or reusable tier sheets that are placed between layers of containers on pallets. This eliminates the need for complex case structures while providing adequate protection and organization during transport.
Solution Approach 2:
Instead of using single large cases for each container type, the invention segments the packaging function into multiple smaller tier sheets that separate layers of containers on pallets. This allows for more flexible arrangement and eliminates the need for re-erecting large case structures.
2Adaptability or versatility
If universal cases are used for different types of spouted bottles, then versatility is achieved, but packing density decreases due to voids and wasted space
Solution Approach 1:
The invention transitions from three-dimensional case structures to two-dimensional tier sheets that separate layers on pallets. This dimensional change allows for more efficient space utilization while maintaining versatility through different sheet configurations and arrangements.
Solution Approach 2:
The tier sheets serve multiple functions: they provide layer separation, protect container spouts, enable efficient palletization, and work with various container types and sizes. This multi-functionality replaces the need for specialized cases for different container configurations.
3Reliability
If manual handling methods are used for spouted containers, then careful placement is achieved, but productivity decreases due to labor-intensive operations
Solution Approach 1:
The tier sheets act as intermediaries that facilitate automated or semi-automated palletization processes. They provide a structured framework that guides container placement while protecting spouts, enabling more efficient handling compared to direct manual manipulation.
Data Source
AI summary
A system for palletizing containers with tier sheets is disclosed. In embodiments, a system includes a pallet; at least two layers of containers, each layer including a plurality spouted containers; and a tier sheet provided between the at least two layers of containers. In embodiments, the tier sheet includes a top portion and a plurality of projections.