CUSTOMER REQUIREMENTS
From the very beginning of the project, DACHSER required a solution capable of meeting extremely complex operational needs:
- FULL AUTOMATION OF THE PALLET PREPARATION AND STABILIZATION PROCESS
- ELIMINATION OF MANUAL WRAPPING AND STRAPPING OPERATIONS
- SUPPORT FOR THE CREATION OF MULTI-PRODUCT DISPLAY PALLETS
- DIRECT INTEGRATION WITH THE CUSTOMER’S ERP SYSTEMS
- FULL TRACEABILITY OF EVERY SINGLE PALLET
- HIGH PRODUCTIVITY OF UP TO 120 QUARTER PALLETS/HOUR
TOSA SOLUTION
The solution developed by TOSA involved the creation of a highly automated integrated line, designed to manage the entire process of preparing display pallets:
- MODULAR BELT CONVEYOR LINE FOR ASSISTED MANUAL PREPARATION
- OPERATOR STATIONS WITH ERP-CONNECTED HMI INTERFACE
- DEDICATED SOFTWARE SYSTEM FOR REAL-TIME OPERATIONAL GUIDANCE
- HIGH-SPEED STRAPPING MACHINE (UP TO 120 p/h)
- HIGH-SPEED WRAPPER WITH 500 mm ROLL
- AUTOMATIC LABELING SYSTEM
- COMPACTING AND RECOMPOSITION STATION ON MASTER PALLET
- FINAL WRAPPING WITH CORNER PROTECTION
The line has also been designed to ensure maximum operational flexibility:
- HANDLING OF MULTI-PRODUCT DISPLAY PALLETS
- BYPASS LINE FOR OFF-CYCLE LOADS
- FULL INTEGRATION WITH CUSTOMER IT SYSTEMS
- CONTINUOUS TRACEABILITY ALONG THE ENTIRE LINE
PARTNERSHIP & DEVELOPMENT
The project represented one of the most complex challenges in terms of software integration and workflow management.
The close collaboration between the TOSA and DACHSER teams enabled the development of an advanced system capable of communicating in real time with the customer’s ERP systems, guiding operators in the assembly of display pallets through intuitive interfaces.
The integration of industrial automation and information systems was crucial for ensuring operational precision, efficiency, and total control of the process.
RESULT
The implementation of the TOSA solution enabled DACHSER to transform a complex, manual process into an automated, efficient, and fully traceable line.
The system ensures:
• optimization of repacking operations
• reduced human error
• increased productivity
• Full visibility and control of flows
A project that sets the standard for integrated end-of-line solutions in the logistics sector.
