High-performance palletizing and depalletizing across four production sites
With the new end-of-line solution, we have created a highly efficient and flexible system across all sites. The standardized palletizing approach combined with tailored depalletizing solutions gives us the performance and reliability we need for future growth.
Task
A leading European manufacturer of meat and charcuterie products aimed to modernize its end-of-line logistics across four production sites in Switzerland.
The objective was to create a future-ready automation concept that increases throughput, ensures process reliability, and supports complex, mixed product flows — while maintaining high hygiene standards.
At the same time, the customer pursued a clear strategic goal:
A standardized palletizing system across all locations, combined with flexible, site-specific depalletizing solutions.
Solution
TRAPO implemented a modular end-of-line system in hygienic design, tailored to each site while maintaining a unified engineering concept.
Standardized palletizing
All four sites are equipped with high-performance layer palletizers featuring:
- Simultaneous palletizing of two layers
- Integrated stacking technology for optimized material flow
- Configuration with one or two palletizing stations
- Reliable handling of both standard and express orders
This ensures consistent performance, simplified operation, and maximum scalability.
Flexible depalletizing strategies
Depalletizing was customized according to site-specific requirements:
- Sites 1 & 2: Semi-automated depalletizing with manual removal of crate stacks and automated downstream conveying
- Site 3: Fully automated layer depalletizing
- Simultaneous handling of two layers
- Automated separation and distribution across multiple lines
- Site 4: Customized solution with simultaneous handling of four crate stacks, including automated separation via transfer system
Despite different approaches, all solutions are based on a shared system architecture, ensuring high availability and consistent process quality.
Smart control and performance
The entire system is controlled via TRAPO software, enabling:
- Full process transparency
- Traceability of all palletizing and depalletizing steps
- Data-driven optimization of performance and OEE
With a throughput of up to 2,032 crates per hour, the solution handles both peak loads and flexible production scenarios.
Results & Benefits
- High throughput: up to 2,032 crates per hour
- Maximum flexibility: handling mixed products and dynamic order priorities
- Process reliability: stable and consistent material flow
- Hygienic design: ideal for food processing environments
- Improved working conditions: reduced manual handling and physical strain
- Scalable concept: future-proof and adaptable to growth
Requirements
The requirements were both operationally and technically demanding:
- Handling of E2 and C2 crates in mixed operation
- Processing of unsorted incoming crate flows
- Reliable handling of high throughput volumes
- Parallel processing of standard and express orders
- Scalability for future performance increases
- Consideration of site-specific space constraints and process differences
- Compliance with strict hygiene standards (stainless steel design)
