In today’s competitive manufacturing landscape, automation isn’t just a luxury—it’s a necessity. For one global leader in flexible packaging, modernizing their palletizing process was a top priority. Faced with a highly manual operation that was inefficient, labor-intensive, and difficult to scale, the company needed a solution that would boost speed, enhance safety, and fit within the tight constraints of a brownfield facility. To bring this vision to life, they partnered with CRG Automation and Alba Manufacturing.
CRG Automation is known for designing sophisticated robotic systems that solve complex operational challenges. For this project, they engineered a fully integrated five-station robotic cell that handled labeling, scanning, sorting, palletizing, and stretch wrapping. Designing this advanced system within the existing facility footprint presented a unique spatial challenge. To overcome it, CRG needed a partner with proven expertise in heavy-duty pallet handling and custom conveyor integration. They turned to Alba Manufacturing.
Alba provided critical conveyor components for the project, including Chain Driven Live Roller (CDLR) conveyors, Thru-Frame Transfers, and Turntables. These solutions enabled smooth and reliable movement of stacked 40” x 48” GMA pallets—each weighing up to 2,100 lb.—throughout the robotic cell. The pallet stacks were transferred seamlessly to the end-of-line stretch wrapper, ensuring continuous operation and eliminating the delays often associated with manual processes.
But this project was about more than just moving pallets. CRG designed a system that elevated safety, performance, and intelligence. The robotic cell was equipped with video-based diagnostics and a custom HMI interface, making it easy to monitor and manage the entire operation. Meanwhile, the integrated labeling and quality assurance functions eliminated repetitive manual tasks, allowing the company to reallocate labor toward higher-value work. The result: a more ergonomic work environment and significantly improved operational efficiency.
From an integration perspective, Alba’s equipment arrived fully prepped—complete with pre-mounted photo eyes and transfer motors wired to junction boxes—eliminating time-consuming commissioning work. CRG praised Alba’s ability to deliver not just quality equipment, but also a hassle-free experience that made system integration smoother and faster.
Conveyor/Product Specifications
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- Five (5) FT251140-4-3S CDLR Conveyors with 90° Thru-Frame Transfers
- Six (6) CDLR Conveyors (Model 251140-4) of Various Lengths
- Two (2) TT251140-4 CDLR Turntables with Electric Rotation
- Rollers on 4″ Centers, 52″ Effective Width, 18″ Top of Roller
Value Added Features
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- Pallet Loading Guides with 45° Taper for the Robot to Locate the Pallet in the Same Position Every Time
- 24 VDC Banner Retro-reflective Photo Eyes with 2-Meter QD Style Cables
- Transfer Motors Pre-wired to a Junction Box
- Transition Rollers for Smooth Conveyance of the Pallets from the CDLR Conveyors to the Turntables
- Fixed End Stops on the Transfer Chains for the Robot to Locate the Pallet
- Pallet Back Stops Painted Safety Yellow
- Alba Dark Blue Paint to Match the Stretch Wrapper
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About Us
Alba Manufacturing, established in 1973, engineers and designs heavy-duty roller conveyor systems. Our systems consist of chain driven live roller (CDLR), zero pressure accumulation, drag chain, gravity, lift and rotate, pallet stackers and dispensers, turntables, chain transfers and transfer cars. Our corporate office and manufacturing facility is located in Fairfield, Ohio, approximately 30 minutes north of Cincinnati, Ohio.
For more information regarding this application/solution, please contact us via phone at 866.252.2634; via web at www.albamfg.com or via email at RockSolidConveyor@albamfg.com.