Unit Load Equipment is used to restrict materials so that they maintain their state and integrity when handled a single load during transport and for storage. If materials are single part or interlocking parts, then they can be formed into a unit load with no equipment



Advantages of unit loads:

• More items can be handled at the same time, thereby reducing the number of
  trips required and, potentially, reducing handling costs, loading and unloading times, and product damage.
• Enables the use of standardized material handling equipment.

Disadvantages of unit loads:

• Time spent forming and breaking down the unit load.
• Cost of containers/pallets and other load restraining materials used in the unit load
• Empty containers/pallets may need to be returned to their point of origin.

Types of Equipment:

Pallet

A pallet is a flat transport structure that supports goods in a stable fashion while being lifted by a forklift, pallet jack, or other jacking device. A pallet is the foundation of a unit load design, which can be as simple as placing the goods on the pallet, and securing them with straps or stretch-wrapped plastic film, or as exotic as a Unit Load Device minicontainer.

While the majority of pallets are made of wood, pallets that are manufactured from plastic, metal and paper can also be found. Each individual materials used has each own pros and cons.

Stringers is a frame of three parallel pieces of timer. Stringer pallets is a continuous, longitudinal, solid or notched beam – component of the pallet used to support the deck components, often identified by location a the outside or center stringer.

The stringer is the board located between the top deck boards and the bottom deck boards. The top deck boards are then affixed to the stringers to create the pallet structure. Stringer pallets is either notched making it a partial 4-way or solid with no notches, are also known as "two-way" pallets, since a pallet-jack may only lift it from two directions instead of four. Forklifts can lift a stringer pallet from all four directions, though lifting by the stringers is more secure.

SLIP SHEET

Used as a unit load support device in vehicle delivery and transportation of products. When slip sheets are supported by a pallet board, roller conveyor surface, flat load carrying surface, or a cart or lift truck, the structural strength of the slip sheet supports the product loads weight. With the slip sheet supported by one of these transportation devices the unit load can easily be transported both internally within a facility and externally between two facility locations.

It is shaped and dimensioned to the size of the product or unit load. The type of slip sheet varies depending on both the number of lip extensions and the material from which it is manufactured.

The variation used would depend on the loading patterns, unit load parameters, and desired maneuverability of the slip sheet/unit load. Normally, the thickness of the slip sheet is <1/2 in. For most warehouses, plant functional material handling equipment, and the travel-path clearances, this fraction of an inch height increase does not stage a problem. When designing an in-house transportation path for the slip sheet unit load, the slip sheet has a 4 to 6 in. lip (tab) that extends beyond one or more of the sides of the slip sheet. The lip extensions permit a push-pull device to lift the slip sheet unit load.

Slip Sheet Advantages:

· Using slip sheets instead of wooden pallets allows for 12-15% more products
in material handling containers
· Slip sheets do not require maintenance, but can easily be replaced
· Significant reduction in material handling costs
· Decreases loading/unloading time by up to 60%
· Weighs 20 times less than wooden pallets, saving shipping weight
· Can be customized to fit any size load
· Eliminates the need for pallet exchange
· Reusable and reliable
· Most are recyclable
· Is cost-effective

Slip Sheet Disadvantages:

· Pallets provide a greater clearance between the floor and the unit load
· Slip sheet usage requires special attachments on transportation devices such
as a lift truck (but are fairly cheap)
· When used alone, pallets provide more structural support than slip sheets
· Pallets are easily compatible with crane devices
· Lift truck attachment reduces load capacity
· Greater load damage
· Slower handling


Types of Slip Sheets

1.) Plastic Slip Sheets

Plastic Slip Sheets are custom designed, die cut flat sheets that are utilized in handling, storage and shipping of unitized goods, replacing traditional pallets and fiber slip sheets. Plastic slip sheets allow you to move packaged goods for less. You will be able to ship more products, in less space, and reduce overall freight cost associated with packaging.

Plastic slip sheets are cost effective and are an excellent alternative to expensive wood pallets and offer many advantages of fiber slip sheets.

2.) Bulk Load Containers

Reusable container used to unitize and protect bulk materials.

Includes drums, cylinders, etc.

Used for both distribution and in-process handling.

3.) Shrink-Wrap/Stretch-Wrap

Used for load stabilization

In shrink-wrapping, a film or bag is placed over the load and then heat is applied to shrink the film or bag; allows irregular loads to be stabilized; manual or automatic; most shrink-wrap applications are being replaced by stretch-wrapping.

In stretch-wrapping, a film is wound around the load while the film is stretched; allows irregular loads to be stabilized; manual or automatic; as compared to shrink-wrapping, stretch-wrapping has lower material, labor, and energy costs.

Stretch wrap is used as a pallet wrap to secure boxes on a pallet during shipment. The elasticity of the film holds the load tight.

Shrink Wrap is typically used when wrapping a single item or product such as CD’s, DVD’s, or gift baskets. A shrink wrap heat gun is used to heat the shrink film which causes it to shrink around and seal the product. Both stretch wrap and shrink wrap can be used to bundle products together for shipping purposes.


4.) Palletizers

Manual palletizing is labor intensive and represents the greatest source of workman compensation claims in the packaging operation.

We offer 2 methods: mechanical and robotic palletizers to help offset this risk and reduce labor cost.


i.) Mechanical Automatic Mechanical

Formed the layer pattern by turning the bags by means of a turning wheel or bar. The bags are then pushed onto a layer forming table from which the completed layer is deposited on the pallet.

These palletizers are programmed for each product and pallet configuration. Once the pallet is complete it is lowered by means of an elevator and exits the palletizer onto a downstream conveyor. Empty pallets are automatically dispersed to the system and slip sheets added when called for. Mechanical palletizers can run at rates of up to 35 bags per minute.




ii.) Robotic Palletizers

Programmed to handle up to 100 different pallet configurations. Rather than turning the bags the robot picks them up and rotates them before setting them down on the pallet.

Robotic palletizers have several advantages over traditional mechanical models, including smaller foot print, lower cost, and significantly less mechanical parts to maintain. Robotic palletizers will run rates up to 22 bags per minute.