The Challenge
In 2023, a client in the United Kingdom asked Rometa for a brand-new, high-output installation aimed at the British market, to manufacture solid blocks of 10, 15 and 20 cm, palletized in a 90 x 90 cm format, on a 2,000 m² site.
The main technical challenge was a special voided palletizing system: creating packs with internal voids/holes in the lower layers to achieve self-supporting, palletless packs, compatible with both blocks and pavers. The concrete plant was completed with a 4-hopper batching unit with a single, integrated loading system. The production target was set at 10 cm solid blocks (18 pieces per cycle), reaching a rate of 3,200 pieces per hour.
The Rometa Solution
To overcome the technical complexity of palletizing different sizes and geometries without losing production pace, Rometa designed, on a custom configuration of the 4050 model (4050S), an advanced handling and packaging system:
Integrated packaging carousel. A carousel system fitted with horizontal and vertical strapping, with pack rotation to allow cross vertical strapping on both sides. It includes a plastic-bag wrapping system and a buffer store for up to 20 packs at the outlet, with the option to switch between voided (palletless) stacking or traditional wooden pallet stacking depending on the order.
Innovative triple voided palletizing system. To avoid reducing or penalising the main machine's cycle time, a process split into three simultaneous stages was implemented: the first palletizer groups and forms the standard (non-voided) layers; the second palletizer (secondary line) independently prepares the voided layer, placing the pieces apart in the required void configuration; the third palletizer, fitted with a special high-security side-clamping gripper, is able to pick up the voided pieces (both blocks and pavers) from their sides, guaranteeing full stability during movement, preventing pieces from falling and adapting to any product geometry.
The Result
The result is a brand-new, high-tech installation, fully automated and run by a single operator from the raw-material intake point through to the output of the finished packs, reaching an output of 3,200 pieces per hour. The client now supplies concrete blocks and sleepers across the whole Bristol region and surrounding areas.
