Keys to automate the packaging of ceramic picking loads

The ceramic and construction materials industry is experiencing a significant transformation in logistics due to the rising demand for warehouse picking orders. As a result, many ceramic manufacturers and construction distribution centers are confronting the challenge of automating the complex process of orders with picking. Until recently, these companies have managed this packaging process using manual or semi-automatic systems. Now, fully automated systems are available to improve productivity, efficiency, and the security of logistics.

As specialists in end-of-line packaging systems, we share in this article the keys to automating this complex picking process with advanced packaging technologies such as Stretch Wrapping and Stretch Hood systems.

What is Picking, and Why is it Key in Ceramic Distribution?

Picking is a fundamental process in modern logistics that involves selecting and preparing products to fulfill specific orders. In the construction materials and ceramics sector, the importance lies in managing various products such as tiles, sanitary items, and building materials, which are often combined into a single pallet based on customer requirements. This method enables companies to optimize shipments of customized orders, enhance transportation efficiency, and cater to the increasing demand for tailored logistics solutions for large retailers and construction projects.

Requirements of the Ceramic Industry: Automation as a Necessity

The growing demand for picking orders in the ceramic, sanitary, and construction materials sectors has led many companies to rethink their packaging methods. Traditionally, these loads were protected using manual or semi-automatic methods. However, to respond to increased production and maintain competitiveness, it has become essential to adopt fully automated solutions.

Ceramic picking presents unique challenges, including:

• Product diversity: Different sizes, weights, and shapes of ceramic pieces require flexible packaging solutions that ensure the safety of heavy yet fragile loads.
• Increased production: Large distribution centers and construction material retailers demand shorter order delivery times.
• Security and stability: These fragile and unstable loads must be perfectly secured to prevent damage during transport.

Solutions to Improve Picking Packaging Processes

Automating the packaging of picking loads enhances efficiency, decreases costs related to manual or semi-automatic labor, and reduces errors and accidents. Some of the key processes that need automating are:

1. Robotic Picking and Load Palletizing: Picking robots are essential for quickly and accurately managing product diversity. These systems optimize pallet space and ensure a stable load arrangement, facilitating subsequent packaging.
2. Automatic Pallet Load Packaging: Once palletized, the load must be securely packaged. Automatic packaging systems offer fast, precise, and adaptable solutions customized for each client’s specific needs.
3. Automated Guided Vehicles (AGVs): To complete the automation cycle, AGVs safely transport loads from the palletizing and packaging line to the shipping area, seamlessly integrating with packaging systems.

Ideal Packaging Systems for Ceramic Picking

But how can such a complex packaging process, often involving loads as small as a single piece, be automated? At Innova, as specialists in protecting all types of loads, we offer several automated solutions for picking.

Automatic Stretch Wrappers

Automatic stretch wrapping systems are one of the most commonly used solutions for picking loads due to their versatility and adaptability. Among the market solutions, two key systems stand out depending on the load protection needs and business requirements:

Ring Stretch Wrappers

Automatic Ring wrappers are a high-performance and secure solution designed for large-volume loads or those requiring special wrapping. This system uses a mobile wrapping ring that continuously applies stretch film around the load, ensuring a uniform and secure wrap. Its versatile design adapts to different types of loads, including unstable or irregular ones, such as ceramic picking loads.

In the case of Innova’s ring wrapper, it includes a double wrapping carriage to increase productivity and offer reinforced wrapping with doble wrapping carriages and a reinforcement roping device.

Advantages of Innova’s Ring Stretch Wrapper:

• Exceptional speed in the packaging process, ideal for high production volumes.
• Flexibility to wrap loads of various dimensions and shapes.
• Automatic top cover applicator for full load coverage.
• Reduced film consumption thanks to the electronic torque control system.

Examples of Ceramic picking loads wrapped with the Ring Wrapper from Innova

Rotary Arm Stretch Wrappers:

The automatic rotating arm wrapper is an effective alternative for productions where high performance is not required. Innova’s arm wrappers feature a patented roping tying system that provides greater security and load fastening.

Innova also offers the Techlite version of its arm wrapper for companies or production types looking to start automation with a simpler yet equally effective model.

Advantages of Innova’s Arm Wrapper:

• Excellent balance between speed and packaging quality.
• Suitable for unstable loads or fragile products requiring additional cord reinforcement.
• Automatic top cover applicator available for all models.
• Greater versatility with Innova’s Techlite model.

The choice between a Ring or Arm Stretch Wrapper will depend on the specific characteristics of the load and the required production level. Do you need help deciding which model is most suitable for your company? At Innova, we can provide consultancy on different packaging systems and wrapper versions without commitment.

Stretch Hood System for Picking

The Stretch Hood system has emerged as an increasingly popular alternative to stretch wrappers for picking protection. Its major advantage over other systems is its ability to fully protect the load with a single film layer, eliminating the need for additional top covers for unevenly shaped loads.

The Stretch Hood system is designed to adapt to the wide variety of sizes and volumes characteristic of picking loads, thanks to the application of Stretch Hood tubular film. Its primary advantage lies in its ability to precisely wrap everything from small individual loads to full pallets, always ensuring maximum and uniform protection.

Advantages of Stretch Hood vs. Other Systems:

• Total Protection: Stretch Hood film offers airtight protection against dust, moisture, and other elements—a crucial advantage for transport and storage in large retail and construction material settings.
• High Adaptability: Unlike some stretch wrappers in the market, Stretch Hood can even wrap very small or low-height loads. Innova’s Stretch Hood system allows the hood to cover the pallet base and can be applied at a very low height.
• Perfect Transparency: Stretch Hood wrapping enhances product presentation and brand visibility, a key factor for Ceramic loads at points of sale, such as distribution centers or large construction retailers.

A notable example is the installation carried out for our ceramic client Grespania, where our Stretch Hood system enabled the company to automate the packaging of ceramic picking loads, improving security and reducing consumable usage.

In summary, automating ceramic-picking packaging is more than a trend; it is a necessity for companies seeking efficiency, security, and sustainability. At Innova Group, we combine advanced technology with our expertise in packaging systems to offer customized solutions that address the industries’s challenges. If you are looking to improve the packaging of your picking loads, contact us and discover how we can help you optimize and enhance your end-of-line process.