Robotic Depalletizing by Layer

Introducing NūMove’s newest layer depalletizing robot tool—built for advanced material handling. This innovative end-of-arm tool allows robot to manage full layers of diverse product types, including closed cases, open cases, wrapped or unwrapped trays, and cartons in trays. As packaging formats evolve, this tool adapts to an even wider spectrum of products by integrating suction, clamping, and bottom forks for secure handling. Upgrading from earlier models limited to suction and forks for closed cases and wrapped trays, this design offers greater adaptability. The three mechanisms work together to ensure reliable operation across various packaging types, meeting the needs of high-throughput logistics environments. This depalletizing tool can handle layers ranging from 30x36 to 44x52 inches, with heights varying between 2 and 20 inches. When paired with a suitable robot, the tool can lift layers weighing up to 600 lbs. The suction system is designed to pick layers with missing products and partial layers. The clamps enable the tool to pick trayed products, while the bottom forks ensure that no products are dropped when the robot moves the layer at high speed. These combined features enable the system to depalletize 3 to 4 layers per minute, which translates to a throughput of up to 2,000 products per hour. This layer depalletizing tool can be combined with a vision system to help the robot localizing exactly where the layer is positioned, even if the top products have shifted during handling. Finally, an unscrambling conveyor can be added downstream, so all products exit the cell single filed and short side leading. | RAPTOR (Robot Arm Picking to Order Release) is an advanced automation solution developed by NūMove Robotics & Vision in partnership with KPI Solutions to transform the preparation of mixed-SKU order pallets for high-volume beverage and beer distribution centers. This dual-robot system combines AI-driven vision technology, adaptive tooling, and intelligent software integration to address one of the most labor-intensive challenges in modern warehousing. RAPTOR benefits include: faster order fulfillment for mixed pallets, reduced labor dependence, increased worker safety from reduced repetitive lifting, and increased order throughput. The process begins with robotic depalletizing, where a high-speed robot equipped with proprietary 3D vision and AI algorithms identifies and localizes individual products on donor pallets, even when packaging graphics change. Products are then organized by SKU into dedicated buffer lanes within a flow rack. This temporary storage helps maximize uptime and improve overall throughput. The robot’s end-of-arm tool integrates vacuum, bottom support, and top clamping to handle diverse packaging formats such as closed cases, open-top cases, wrapped trays, and carton boxes in trays. For returnable shells containing loose bottles, detachable connectors are automatically added to ensure secure handling. This design enables high-speed operation while maintaining product integrity. On the opposite side of the buffer flow rack, a second robot performs robotic palletizing, retrieving items one at a time to build dense, stable mixed-SKU pallets. Its gripping system mirrors the depalletizer’s versatility, preventing drops even with damaged packaging. Advanced cubing software determines optimal pallet layout, applying stacking rules for product type, size, and weight to meet store requirements. The palletizing robot then retrieves items from the buffer in the precise sequence calculated by the cubing algorithm to build a dense and stable order pallet. RAPTOR also accommodates starter pallets with pre-built layers, using vision technology and AI to verify layer integrity and measure height for precise stacking. A key differentiator of RAPTOR is its seamless integration with KPI Solutions’ Opto™ Software, which acts as the link between the distribution center’s WMS and the robotic system. Opto’s Warehouse Execution System (WES) orchestrates real-time order management, SKU prioritization, and robotic task sequencing, ensuring RAPTOR operates in perfect harmony with upstream and downstream processes. This integration delivers significant benefits: dynamic order release based on demand, real-time visibility through intuitive dashboards, and scalable architecture that adapts to changing SKU profiles and multi-site deployments.