Palletizer / Depalletizer Upgrade Catalog

bwintegratedsystems.com

Upgrade your existing packaging equipment Upgrading 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, 4 Palletizers (Case)...... 8, 9 Allen-Bradley 1791-I/O Blocks - Discontinued . 3 Adjustable Divider Lanes...... 8 Allen-Bradley 1794-ASB module - Discontinued.3 Automatic Divider Adjust...... 8 Allen-Bradley PanelView Plus Touch Screen. . .3 Beaded Rail Case Guides...... 8 Allen-Bradley PLC...... 3 Center-Drive with Nose Over Transition. . . . 8 Allen-Bradley VFD...... 3 Floor Level Dirt Sheet Inserter...... 9 Hydraulic to Electric...... 3 Maximizer Dual Bridge Turners...... 9 Industrial Communication Router...... 4 Pattern Addition/Change...... 9 Main Control Enclosure Replacement. . . . . 4 Skate Roller Case Transfer...... 9 Safety Light Curtain...... 4 Upper Lift Extended Pusher...... 9 Palletizers (RoboMax)...... 9 Robotic Case Turning and Pattern Forming . . .9 Global Markets / Manufacturing. . . . 11 Product Changeover...... 10 Adjustable Case Palletizer Infeed ...... 10 Global Manufacturing...... 11 Digital Counter...... 10 Global Markets...... 11 Safety...... 10 Safety Guarding for Empty Pallet System. . . .10 Safety Upgrade for Pallet Discharge Tunnel . . 10 Mechanical Upgrades. . . 4, 5, 6, 7, 8, 9, 10 Sheet Handling...... 10 Depalletizers (Bulk)...... 4, 5, 6 Autoserter...... 10 3-Position Sweep...... 4 Indexing Separator ...... 10 Destrapper ...... 4 Dunnage Bin...... 4 Dunnage Bins - Offline & Inline Overhead . . . 5 Height Paddle Detection ...... 5 Lift Hoist Drive...... 5 Manual Strap Chopper...... 5 Robotic Unwrapper...... 5 Sweep...... 5 Sweep Pivoting Pusher...... 6 Top Sheet Hold Down...... 6 Pallet Changeover...... 6 Auto Adjust Empty Pallet Guides...... 6 Main Lift Auto Adjust Pallet Guides...... 6 Main Lift Pallet Stops...... 6 Pallet Handling...... 6, 7 Pallet Conveyor...... 6 Pallet Stacker/Unstacker...... 7 Palletizers (Bulk Can) ...... 7, 8 Airliner...... 7 Automated Top Frame Handling...... 7 Dedicated Stagger Head...... 7 Empty Pallet Magazine...... 7 Servo Pallet Transfer...... 7 Servo Positioner and Stabilizer ...... 8 Top Frame Handling...... 8

bwintegratedsystems.com Electrical Upgrades 3

Electrical Upgrades Allen-Bradley PanelView Plus Allen-Bradley VFD Touch Screen New drives operate faster and Allen-Bradley 1791-I/O Blocks - This upgrade will replace obsolete perform better than old, obsolete Discontinued touch screens, pushbutton type drives. They provide “safe torque off” With the discontinuation of the block, control panel, or data liners with a function as an option, if required, and pictured below, we recommend touch screen type. An operator can have better and more programming completing a controls upgrade, which choose between systems screen, run options. They also offer ethernet IP will replace outdated components screen, product sheet screen and a communication, if required. with up-to-date ones. diagnostic history screen which allows operator communication with the PLC and eliminates the need for a laptop computer to make adjustments.

Allen-Bradley 1794-ASB module Allen-Bradley PLC Hydraulic to Electric - Discontinued If you have remote I/O in your existing Can replace a single hydraulic With the discontinuation of the below PLC and the adapters fail, purchasing application or an entire machine’s module, we recommend completing used ones from the internet may hydraulic system. Reduces or a controls upgrade, which will replace prove expensive, unreliable, or non- eliminates potential hydraulic leaks/ outdated components with up-to- functional. We recommend our spills. date ones. 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.

bwintegratedsystems.com 4 Electrical Upgrades / Mechanical Upgrades - Depalletizers (Bulk)

Industrial Communication Safety Light Curtain Destrapper Router The one-way safety light curtain can Automates the removal of the straps Combines a modem and an IP router be fit onto any entrance or exit point from your empty container pallet. for both serial and Ethernet PLC of a palletizer or depalletizer, and can The Destrapper cuts the straps and protocols allowing a qualified person be a standalone upgrade or as part automatically disposes of them into a to remotely observe and make of a complete control package and large container. It will integrate into changes to the PLC program. Category 3 safety upgrade. an existing depalletizer and comes with its own control package.

Main Control Enclosure Mechanical Upgrades Dunnage Bin Replacement Upgrades existing dunnage bins with The new panel comes with a PLC. Depalletizers (Bulk) pneumatic operated doors. Bombay doors can also be added to better This upgrade will include a fusible 3-Position Sweep disconnect, panels, overload handle a group of sheets or top This sweep upgrade allows for protection, circuit breaker, motor frames. separate slip sheets, and top frame starters, contact blocks, terminal positioning. The top frame and top strips, power supply, relays, wire sheet can be picked simultaneously ways, miscellaneous components, with this upgrade. and a new documentation package with new electrical schematic. Bombay Doors Top frame deposit posion Pneumacally Operated Bin Doors

3-posion Sweep

Slip sheet deposit posion Manual

bwintegratedsystems.com Mechanical Upgrades - Depalletizers (Bulk) 5

Depalletizers (Bulk) Lift Hoist Drive Robotic Unwrapper This upgrade, for ACME/Simplimatic Our Unwrapper integrates into Dunnage Bins - Offline & Inline 400D Bulk Depalletizers, replaces an existing depalletizing line and Overhead the expensive, obsolete, and long removes the stretch wrap from the For additional sheet storage and top lead 2-speed lift motor and reversing pallet. It comes complete with safety frame storage, this upgrade offers starter with a standard AC motor and guarding and control interface. high-level, mid-level, and low-level new Allen-Bradley frequency drive for access. Automatic discharging of added speed and control. Optional loads is also available. encoder control is available.

Top frame bin Slipsheet bin

Height Paddle Detection Manual Strap Chopper Sweep Do you have a need for multiple When an operator has manually Improve speed and tier sweeping ability container heights. With this upgrade destrapped a pallet., the manual strap while improving overall efficiency. an operator selects height settings chopper will chop up straps and put Upgrade can include new belt drive (infinite size adjustment within range). them into a large container. package with shaft-mounted SEW It may include electrical upgrade gearmotor. New sensors for position with a PanelView graphic terminal on control are included. New sheet pick- some models. up and top frame pick-up. 2-position or 3-position sweeps. Available in linear shaft or high-speed roller wheel configurations.

bwintegratedsystems.com #6 Mechanical Upgrades - Depalletizers (Bulk) / Pallet ChangeoverProduct / CategoryHandling

Depalletizers (Bulk) Pallet Changeover Main Lift Pallet Stops Automatically adjustable for various Sweep Pivoting Pusher Auto Adjust Empty Pallet Guides positions, and can be controlled The sweep pusher can be upgraded Replaces slots and slides for repeated through the HMI (may require HMI with a pivoting pusher and sensors empty pallet size changeover. upgrade). that is used to detect pushing jams, Changeover can be done with a and protect the machine before press of a button on the HMI screen, damage occurs. simplifying changeover - especially multiple positions.

Top Sheet Hold Down Main Lift Auto Adjust Pallet Pallet Handling This mechanism will secure the sheet Guides on top of the pallet, during the last If running multiple pallet sizes, the Pallet Conveyor sweep cycle, and is recommended lift pallet guides can be upgraded Improved rugged design and for the Wyard BDA-3200. to tool-less manual or automatic construction. Deck plate design changeover. 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.

Last sheet hold down

Sheet clamps

bwintegratedsystems.com ProductMechanical Category Upgrades - Pallet Handling / Palletizers (Bulk Can) #7

Pallet Handling Automated Top Frame Handling Empty Pallet Magazine Top frame dispenser automatically The upgrade will lift a single pallet, Pallet Stacker/Unstacker places the top frames onto the pallet instead of an entire stack - eliminating Updated pallet stacker/unstacker outside of the hoist. It reduces pallet hazardous loads overhead. Includes design improves speed and stacking changeover time, when compared to guarding and safety light curtain for ability. Minimum floor space is manual operation. added safety. required with increased efficiency.

Palletizers (Bulk Can) Dedicated Stagger Head Servo Pallet Transfer All machined parts are on exact Precise movement of the pallet with Airliner centerlines as pattern and can controlled start and stop with servo. Produces void-free patterns. High- diameter. Provides a smoother and Replaces the old, dual-cylinder style pressure zones allow cans to faster operation than older stagger pusher with a single-cylinder linked effectively meter into various lanes. heads. pusher or servo-actuated pusher. This reduces or eliminates the need The servo upgrade is faster than the for an operator at the top of the single cylinder upgrade. Includes machine. Includes removable deck. robust framework.

bwintegratedsystems.com 8 Mechanical Upgrades - Palletizers (Bulk Can / Case)

Palletizers (Bulk Can) Palletizers (Case) Beaded Rail Case Guides Assists in transferring cases during Servo Positioner and Stabilizer Adjustable Divider Lanes pattern forming. Reduces turned Efficiently stabilizes and handles tall Up to nine lanes total, of which six cases, and the risk of potential cans. Increases the layer speed of lanes can be adjusted. The adjustable package damage. 7-10 layers per minute, depending divider lanes put the cases where the upon can height. turners will be positioned.

Beaded Rail Case Guide

Top Frame Handling Automatic Divider Adjust Center-Drive with Nose Over The head and lifting area are Upon selecting the pattern from Transition upgraded - replacing the old design the HMI, the six adjustable lanes Assists in transferring cases during (cam followers riding on a tube) with will be automatically adjusted. This pattern forming, and as a result, a new design featuring a profiled rail eliminates risk of operator inputting filler rollers are eliminated. Prevents and bearing. The new head is made incorrect settings, or forgetting to narrow cases from tipping at transfers, of aluminum extrusion. change settings. This upgrade applies and smooths product travel over to the Maximizer palletizer. transfer points.

bwintegratedsystems.com Mechanical Upgrades - Palletizers (Case / Robomax) 9

Palletizers (Case) Pattern Addition/Change Upper Lift Extended Pusher Add a new pattern or change an This upgrade, for the Maximizer Floor Level Dirt Sheet Inserter existing pattern. This upgrade is palletizer, provides additional area to Adds bottom sheets to pallets, and dependent upon the pattern addition/ allow for greater flexibility in pattern can also replace an existing bottom change needed, and may require configurations. sheeter. other upgrades to complete.

Maximizer Dual Bridge Turners Skate Roller Case Transfer Palletizers (RoboMax) Replaces outer turners for faster, Improves efficiency of product more-efficient, turning of product. movement across conveyors, and Case Turning & Pattern Forming Features hand-crank adjustment with improves case transition during Robots replace divider and bump dial indicators, low-pressure shock- pattern forming. turners, providing gentler handling absorbing turners. Allows turners to of product, reducing maintenance be put where the cases need to be. 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.

bwintegratedsystems.com 10 Mechanical Upgrades - Product Changover / Safety / Sheet Handling

Product Changeover Safety Sheet Handling Adjustable Case Palletizer Infeed Safety Guarding for Empty Pallet Autoserter Improves infeed changeover for System Servo-driven, chain and spring timing. cases and keeps cases on machine Provides the greatest personal Arm is extruded for faster handling centerline after adjustment. Optional protection from pinch points and of sheets. Sheets are handled offerings include: Case hold-down bodily injuries. with suction cups. The Autoserter that can prevent case rolling or tip- works especially well when used overs, and case pairing for improved in conjunction with the Indexing speed of small case handling. Separator.

Digital Counter Safety Upgrade for Pallet Indexing Separator Can be added to your changeover Discharge Tunnel Allows for separating of layer pads points - eliminating start-up delays Includes extended guarding, plus on automatic machines. Increases due to adjustment accuracy. a one-way light curtain. It can be the reliability of the Autoserter, while part of a complete Category 3 safety eliminating double-sheet picks, control upgrade, or a stand-alone especially with new, sheared stacks of upgrade. sheets.

bwintegratedsystems.com ProductGlobal Markets Category / Manufacturing Page11 #

Global Markets BW Integrated Systems provides diverse solutions to a variety of market segments around the Globe: BWPackagingSystems.com

• Container Manufacturing • Wine and Spirits FILLING, SEALING, • Food • Home and Personal Care SEAMING & CAPPING • Beverage • Industrial and Automotive • Beer • Paper • Dairy • Bakery and Confectionary Rigid Form-Fill-Seal | Rigid Fill-Seal Complete Line Integration synerlink.com

Filling | Capping | Seaming Labeling | Centrifuge psangelus.com

Global Manufacturing FLEXIBLE PACKAGING BW Integrated Systems has seven global manufacturing facilities.

• Romeoville, IL USA • Lynchburg, VA USA • Doncaster, S. Yorkshire UK • Minneapolis, MN USA Vertical Form-Fill-Seal | Horizontal • Fergus Falls, MN USA • Reedley, CA USA Form-Fill-Seal | Pre-made Bag Filling • Loveland, CO USA Bag Converting | Product Feeding & Weighing | Bag Conveyance & Palletizing bwflexiblesystems.com

LABELING & SLEEVING

Labeling | Sleeving | Converting accraply.com

END OF LINE & SYSTEMS INTEGRATION

Palletizing | Depalletizing Feeders & Placers | Cartoning Case Packing | Bliss, Tray & Contact one of our representatives today to set-up an appointment Case Erecting | Conveyance & Controls | Can Handling | Can End to review your current needs for any of the above brands along with Handling | Robotic Solutions ACME and Simplimatic Wyard to name additional. Systems Integration bwintegratedsystems.com

1305 Lakeview Drive Plumtree Farm Industrial Estate Romeoville, IL 60446 USA Bircotes, Doncaster t. +1 (630) 759-6800 South Yorkshire DN11 8EW ENGLAND t. +44 (0) 1302 711056