Case Studies Of Industrial Robots

Robots in action can be found everywhere. Robot Manufacturers give examples of robot applications in different industries.

Kawasaki, Germany - IFR Partner

It's all about pallets

In the middle of the Emsland lies the Dörpener Palettenfabrik (DPF), a pallet manufacturer which is able to produce up to 6,000 pallets a day with the help of the latest Kawasaki robot technology. Together with their system partner VANDERLOO GmbH, Messrs. Kawasaki Robotics have designed and built a fully automated production line for the manufacture of pallets for DPF.  

The VANDERLOO GmbH with its Head Office in Saerbeck has specialized - among others - in the design and construction of fully automated pallet production systems, a point which tipped the scales when implementing the complex project.

Selecting the robots

When searching for the fitting robots, the Z series of Kawasaki was chosen. The Z series is composed of robot arms particularly well suited for handling and palletizing tasks. The user may select the model best fitting his tasks and requirements from a large variety of models with payloads between 130 kg and max. 300 kg as well as different arm lengths. Reduced cycle times, a large work envelope due to long reach and small dead space, low power consumption as well as small footprint were further specifications matching the requirement profile.

Pallets for the paper industry "Just in time" is the magic word for the production of pallets for the paper industry. Before a paper mill starts the production of a batch, the matching pallet is ordered. This pallet must then be produced and delivered within 24 hours. As different pallet sizes are required according to the paper size, the system is in the position to produce various formats from 460x580mm to 1900x1900mm. The exact dimensions for the pallet are provided online and are directly sent to production.  Here, all orders received on one day are registered and compiled. A special software prepares the production in such a perfect manner that as little cuttings (waste paper) as little occur.

Mobile ContainersCutting and sorting

Before the manufacture of the pallets can be started, the individual parts must be cut to size. For this purpose, the lumber is fed to the production line on mobile containers. 

In the cutting process, the individual parts for the top surface of the pallet are produced which are then compiled on a conveyor belt.

Kawasaki Robot type ZX 130A Kawasaki Robot type ZX 130 transports lumber sections not required for the current production in a lumber storehouse.


Configuring, manufacturing, packing

The compiled top surfaces as well as the pallet body are then fed to the actual pallet production line on a conveyor belt.

Kawasaki robot type ZD 130Subsequently, a further Kawasaki robot type ZD 130 - equipped with a vacuum gripper - precisely positions the top surfaces.  

After that, both parts of the pallet are fixed to each other by means of an automated nailing device. The finished pallets leave the production area.

A Kawasaki robot ZX 130 L compiles the respective commissions which will then directly be loaded on trucks for further transport in the distributing warehouse.

 Kawasaki robot ZX 130 L

The conclusion

In hardly one year, this complex and modular production plant was realized; it provides the customer with a high degree of automation and thus saving potential due to its holistic and future-oriented design and operation.

Maik Althermeler"Highly flexible and efficient production systems do no longer function without the application of robot technology these days", says Maik Althermeler, Managing Director of VANDERLOO GmbH.

"What persuaded us in particular were Kawasaki's simple programming, the robustness of the robot arms required in view of the environmental conditions as well as a perfect information exchange which in the end granted the due and faultless conversion of the project."


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