From Container to Pallet: The Automated Inbound Solution
Share on
In the world of distribution, the receiving dock has long been the most disconnected part of the warehouse. While the rest of the facility hums with automated storage and retrieval systems, the inbound bay often remains a chaotic scene of manual unloading, sorting, and restacking.
For site managers in Auckland, Sydney, and Melbourne, this "gap" in automation leads to bottlenecks, high labor costs, and inconsistent inventory data.
At Automate-X, we are proud to introduce a comprehensive new workflow that finally closes this loop. By combining the mobile agility of the RockyOne series with intelligent sorting, we can now offer a fully integrated warehouse automation solution that takes your product from the shipping container to the pallet without a human hand touching a box.
The Problem: Loose Loads and Labor Pains
Loose-loaded containers are the standard for maximizing freight efficiency coming into NZ and AU. However, unloading them is back-breaking work. It involves:
- Manual Unloading: Physically pulling varying cartons from a wall.
- Identification: Scanning barcodes to verify SKUs and batch numbers.
- Sorting & Palletizing: Re-stacking goods onto pallets for storage.
This multi-step process is slow, prone to error, and a leading cause of workplace injury.
The Solution: A Symphony of Robots
Our partners at XYZ Robotics have developed a system that automates this entire sequence. Here is how we integrate it into your facility:
Step 1: Intelligent Extraction
The process begins with the RockyOne robot. Unlike fixed machinery, this mobile manipulator drives directly into the container. Its advanced 3D vision system allows it to pick multiple boxes at once—even from irregular stacks—solving the complex "Tetris" problem of robotic truck unloading.
Step 2: The Digital Handshake
Once unloaded, cartons are placed onto a conveyor and passed through a five-sided barcode scanner. This is crucial for compliance. The system instantly verifies the SKU ID and batch number, rejecting any anomalies before they enter your inventory.
Step 3: Precision Palletizing
The final piece of the puzzle is the RockyOne SE. After the goods are sorted, this specialized unit builds the final pallet. What makes it unique is its reorientation capability. It can rotate items mid-air to ensure barcodes face outwards—a critical requirement for retail-ready displays and automated storage compliance.
Why This Matters for ANZ Operations
We are seeing a shift in the local market. Logistics providers are no longer looking for "point solutions" (just a robot arm); they want "process solutions."
By implementing this end-to-end system, Automate-X helps you align with:
- Global Safety Standards: Removing staff from the container reduces exposure to heavy lifting, helping you meet strict ISO 10218-1 safety requirements for industrial robots.
- Ergonomic Goals: Automating repetitive tasks is the single most effective way to lower injury rates, consistent with WorkSafe NZ guidelines for manual handling.
- High Throughput: With real-world speeds of 400 to 700 cases per hour (as seen in deployments in Germany and the US), this system can turn around a 40-foot container in under two hours.
Your Partner in Integration
Bringing this technology to New Zealand or Australia requires more than just shipping a robot. It requires a partner who understands your WMS, your safety protocols, and your floor plan.
As your local system integration specialists, Automate-X handles the entire project lifecycle—from the initial simulation to the final safety sign-off.
The disconnect between unloading and palletizing is a problem of the past. If you are ready to modernize your inbound operations, let’s build a solution that works for your site.
Contact Automate-X today to discuss your inbound logistics strategy.