MATERIAL HANDLING EFFICIENCY
AND UTILITY
Damage Protection
A master carton is a shippable corrugated carton that contains one or more identical selling units. It is used to protect products from damage due to rough handling while being transported and stored in the logistical system. Pilferage issues are being controlled by utilizing master carton. The selling units contained within a master carton may be individual pieces referred to as ‘eaches’ or a number of smaller multi-piece containers called ‘innerpacks’.
The master carton must meet a minimum single wall corrugated carton specifications of adequate construction for conveyance and floor loading. The carton must contain a seal of certification listing its bursting and weight constraints as defined by the National Motor Freight Classification.
The logistical productivity, utility and efficiency are influenced by the logistical packaging of the products. The entire logistical operations are affected by the packaging utility ranging from the incoming activity to the outgoing activity.
Cube utilization can be improved by utilizing small size of logistical package.
Unitization
Unitization describes the physical categorization of master cartons into one confined load for material handling and transport. An example of unitization includes the palletization concept.
Palletizers are used for load formation. There are three general methods of palletizing unit loads:
1. Manual Palletizing
Operators arrange items into the desired pattern used to form the unit load. Since the ergonomics of loading and unloading are important (e.g., vertically, the prime working zone is between the knees and the chest; horizontally, reaches of more than 24 in. with a load should be avoided), lift and turn tables are often used.
Semi-mechanized palletizers requires operators to arrange items into the desired pattern for each layer of the unit load and a powered device is used to transfer layers onto a pallet and then lower the load for the next layer.
2. Robotic Pick and Place Palletizers
Robotic Pick and Place Palletizers is fully automated device to build unit loads. It is used when flexibility is required (e.g., the "Distributor’s Pallet Loading Problem"). Greatest limitation is capacity, typically 6 cycles per minute; capacity is determined by the number of items handled with each pick operation.
Operators arrange items into the desired pattern for each layer of the unit load and a powered device is used to transfer layers onto a pallet and then lower the load for the next layer.
3. Conventional Stripper Plate Palletizers
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Conventional Stripper Plate Palletizers are a fully automated device to build unit loads. It is used when high throughput of identical loads is required (e.g., the "Manufacturer’s Pallet Loading Problem"). Capacity is typically greater (30–180 items per minute) than pick and place because an entire layer is placed on the load at one time; not as flexible as pick and place. Preformed layer of items (cases) are indexed onto the stripper plate (or apron); when properly positioned over the pallet, the apron is pulled out from underneath the layer to deposit the layer onto the pallet.
"In-line" pattern formation (top picture)—flexible patterns are not possible; ideal for high speed operation (up to 180 items per minute); takes up more room (larger machine) than right angle. "Right angle" pattern formation (bottom picture)—very flexible patterns are possible; can handle a wide variety of case sizes and types; limited capacity (up to 80 items per minute); compact design.
Containerization
Containerization is a system of intermodal freight transport cargo using standard ISO containers that are loaded onto vessels and trailers.The types of containerization include rigid containers, non-rigid containers, unit loads, load securing, unit-load platforms, master carton stacking.
Rigid Containers
Rigid containers are simply thicker gages of foil that have been formed into semi-rigid containers to bring the convenience of modern food technology into our homes, schools, and restaurants.
Rigid containers, like foil sheets, provide an ideal barrier to moisture, light, and air. Rigid containers are perfect for holding leftovers and catered food items because, unlike other types of containers, rigid containers do not get soggy or wet and they can be easily recycled.
Rigid Steel Containers
Rigid steel containers feature corner columns made of structural angle or steel tubing, with welded stacking plugs. The columns transmit overhead load weight directly to the floor, thus these containers can be stacked higher than light duty rigid without corner columns. Stacking heights are limited only by the dimensions of the stacks, the lift height of your fork trucks, and the clear height of the facility.
Due to the column transfer of overhead load weight, rigid containers can be ordered with a lower capacity rating than standard containers. Each unit is capacity rated by the weight of the contents of each individual unit, while with other designs the containers would have to be rated to carry the cumulative total weight of all units in a stack.
Rigid steel containers are available in a wide variety of constructions, capacities, sizes, quantities, and colors, to customer specifications. Many options are available, including drop gates, skid bars, for stirrups, fork pockets, crane eyes, etc. Rigid steel containers are an excellent solution to a variety of material handling applications.
Load Securing
Long Steel
Steel Roll
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