Double Pallet Recycling System: Save 5% Space, Automatic Return Solution Details

I do not know if you have ever stood in the workshop worried? Look at the pallet full of crowded not even a place to turn around, manual handling tired and sweaty but also the old jam - at this time if someone said to you "a different way!Save 5% space and also fully automate tray return"Believe it or not? Don't tell me, there really is such a system, and today I'll take you through its doors!

First, the traditional single-level system: pain points solid, space waste is too obvious

You've seen a lot of single-level conveyor belts, right? The pallets go in a straight line, and at the end of the line they have to be moved back to the starting point. Manual handling alone takes upLogistics Costs of 30%Not to mention all those unused trays stacked in the corner -Less than half of the actual utilisation rate.

Take a real example.: A car factory is shutting down every day because of tray jams.3.5 hoursA year down the line.$800,000 down the drain.Why is that? Why all the fuss?The hardness of the single level layout is too obvious::

Waste of space: The return aisle takes up 20% of shop floor space, and the aisle has to be left open for manual work areas;
Not as efficient as it could be.: Manual handling slows down the pace, with fewer flows per hour on average50 pallets.;
High pallet wastageThe rate of scrapping in a year can be as high as15%.

Let's be honest.This is not production, it's just money!

Second, how does the double-deck system work? Lifting cylinders + sprockets work together to save space and energy

The core idea is actually quite straightforward -Stack "outbound" and "return".! Take a look at the classic design of a 2021 patent (Figure 1):
https://example.com/double-layer-pallet.jpg
Schematic diagram of the structure of the double pallet circulation system (Figure 1)

Four steps in the workflow::

be employed at a higher level: Pallet loads inupper zoneRun an assembly line and work from station to station;
Decline in arrivals: at the end of theLifting seatIt is lifted by the cylinder, catches the pallet and lowers it to the lower level;
empty tray reflux (idiom); fig. empty-handed:.reversing motorDrive sprocket, pallet entrylower conveyor beltRunning back to the start on empty;
return to the battlefield: The starting lift seat lifts the pallet to the upper level and proceeds to load the work.

The key space-saving design is here👇

devise	single layer system	two-tier system	Save on results
reflux channel	Separate channel required	Shared vertical space between upper and lower floors	Province lateral area 5%
Number of pallets	100%	60% only	Buy 40 less per 100 trays
human intervention point	terminal handling	Fully automated, no need for manual handling	Less 2 porters

A lithium battery factory measured data is even more alarming.Pallet flow time reduced from 8 seconds to 2 secondsThe annual maintenance fee has also dropped70%--That's a lot of money to put in, and a lot to pay back.8 months.

Third, 2024 upgraded version: double shifting table design, the speed of another 40%

You think that's the end of it? This year's new patents have done it again.Tougher automatic reflux solutions--Double shifting table + magnetic positioning!

Conventional liftsSlow as an old ox pulling a cart: pallets in → down → out → up...It's a two-minute trip.. And the new design works directly with two sets of organs:

Gemini: twoFirst transfer stationCan open and close - close to receive the tray, open to give way to the lower level;
Magnetic stabilisation: Shift table built-inmutual attraction of magnetic massesThe vibration is no more than a runaway;
Guidance Chute Escort: The side sliders snap into the guide slots and move up and down steady as an old dog.

How powerful is the effect?An actual test in a storage centre:

reflow rate: from 120 torr/hour to200 trays/hour.;
failure rate: Loose bolts causing downtime? Doesn't exist!Jams go straight to zero..;
rapid exchange of discs: Removal of pallets compressed from 40 minutes to5 minutes..

personal viewThis design is wonderful in that it breaks down "motion" and "static" - the lift is stable when the transfer table is moving, and vice versa, which makes it much more flexible than old-fashioned monolithic lifts! too much!

Intelligent control: linear path + double speed turntable, error less than 0.5mm

System smart to make fewer mistakes! 2025 steel company patents of theLinear reflux + two-speed controlPull the accuracy full straight away:

Go straight and don't go round corners.: Empty pallet awayPure linear roller conveyorRatio Curve PathTime Saving 27%.;
Double-speed turntable controlturntableangle encoderHigh-speed rough adjustment + low-speed fine adjustment, positioning error ≤ 0.5mm;
Screw locator lockoutThe screw clamps "click" into place, so there's no way to wiggle them out of place.

After a Baosteel branch plant used the system.The efficiency of steel coils out of the warehouse went straight up by 30%--- Empty pallets are never stuck in B waiting for A to dry out.

V. Industry applications: from condiments to car factories, saving real money

This routine is inFMCG, automotive, electronicsThe industry is simply killing madness:

condiment factory: Receiving time cut out90%The packet breakage rate dropped from 8% to3%.;
home furnishing business: Warehouse space released15%Change the three-dimensional warehouse and double the ping efficiency;
automobile assembly line:.Elimination of manual staging areasThe assembly line is 20 metres shorter.

Why do people rush to use it?Just by the way it puts "(of assets) liquid"and"wait for"This pair of enemies split - the upper flow when the lower layer is "waiting", but waiting for the process of silent return flow, not at all delayed!

Six, maintenance tips: 3 strokes to extend the life, not to spend a lot of money can also be saved!

Even if you can't afford to change your system for the time being, doing these three things on a daily basis can stillDrop 22% failure rate::

Weekly track clearance: Take an air gun and blow on the conveyor belt seams, debris stuck in the bearings is the worst;
Monthly backlash adjustment: Plug gauge inserted into gear seam super0.3mm immediately tightDon't wait for broken teeth before you cry;
Quarterly grease change: Recogniselithium grease(-30℃~120℃ to carry it), ordinary butter dries in three months.

And finally, something dry.: A two-tier system is not simply "adding a layer", it isTrading vertical space for horizontal efficiency. In the future, I'm betting it will be the same asPallet cycle rentalCombination - companies do not even need to buy pallets, directly rent smart pallets with chips, saving money to engage in automation, that's the real aroma!