AARS-P

AARS-P – Automatic Application of Top-Cover Material to Pallets

AARS-P is an automatic applicator designed for the crosswise application of top-cover material to the upper surface of a palletised load. The machine can work with top-cover film, paper, Miralon foam or jute mesh and is designed for direct integration into conveyor systems of automatic packaging lines.

AARS-P automatically detects the height of the palletised load, unwinds the preset length of material, measures it precisely, separates it using the cutting system and subsequently applies the prepared sheet to the top of the pallet. The entire process is carried out automatically without the need for manual operator intervention.

Automatic Pallet Covering Directly in the Packaging Line

The AARS-P structure consists of two steel columns and a crossbeam positioned alongside the conveyor line. A horizontal carriage carries the roll of top-cover material and ensures its precise crosswise application above the pallet.

This solution allows the applicator to be integrated directly into an automated packaging workstation, for example before subsequent pallet wrapping with stretch film or another packaging process.

Four Automatic Application Steps

The AARS-P operating cycle is designed to ensure precise and repeatable application of the material:

• Pallet height detection – a photocell automatically detects the height of the palletised load and positions the applicator at the correct working height.
• Material unwinding – the motor unwinds the precisely preset length of film, paper, Miralon foam or mesh.
• Sheet clamping and separation – movable clamps secure the material and a pneumatically driven steel cutting disc separates it.
• Application to the pallet – the horizontal carriage moves the prepared sheet above the pallet and places it onto the top of the load.

Precise Measurement of the Applied Material

The length of the applied sheet is set according to the specific pallet and the required coverage. Precise measurement is ensured by incremental sensors on the motors, which monitor the length and position of the material throughout the operating cycle.

This enables repeatable application while ensuring efficient use of packaging material without unnecessary overconsumption.

Material Width from 700 to 1,300 mm

In its standard configuration, AARS-P is designed for top-cover material with a width of 700 – 1,300 mm. The supported inner core diameter is 70 – 105 mm, while the maximum outer roll diameter is 600 mm.

The unwinding speed is adjustable by means of a frequency converter up to a maximum of 0.2 m/s.

Pneumatic Cutting System

Precise separation of the applied sheet is performed by a 750 W pneumatic motor with a steel cutting disc. The cutting system operates at a pressure of 5 bar.

Once the preset length has been unwound, the movable clamps stabilise the material and the cutting disc automatically separates it. The prepared sheet then continues to the application position above the pallet.

Mechanical Roll Centring

For precise material guidance, AARS-P is equipped with mechanical roll centring within a range of ± 50 mm. This adjustment makes it possible to correct the position of the roll and ensure accurate placement of the applied sheet in relation to the palletised load.

Automatic Material Monitoring

The system monitors the condition of the top-cover material and can signal when the material has run out or torn. This allows the operator to respond in time and prepare a new roll without unnecessarily extending packaging line downtime.

Top-Cover Film

Top-cover film protects the upper surface of the pallet against dust, moisture and contamination. It is particularly suitable for applications where the subsequent packaging process provides complete wrapping of the pallet with stretch film.

Paper

Paper can be used as a separating or protective layer in selected industrial applications. The specific configuration of the applicator is adapted to the properties of the material being used.

Miralon Foam

Miralon foam creates a soft protective layer suitable for products sensitive to scratching or pressure. It is particularly useful for products whose surfaces need to be protected during subsequent packaging, handling or transport.

Jute Mesh

Jute mesh provides a breathable covering suitable for materials where air circulation needs to be maintained. AARS-P enables automatic measurement, separation and application using the same operating principle as with the other supported materials.

Option to Work with Two Different Materials

AARS-P can optionally be equipped with a second register. The additional roll makes it possible to use two different top-cover materials within a single workstation.

Depending on the requirements of the specific packaging process, combinations can include, for example:

• paper + film – a separating layer combined with protective covering against moisture,
• Miralon foam + film – soft surface protection combined with an external protective covering,
• mesh + film – the option to choose between breathable and enclosed covering.

SIEMENS S7 Control System

The applicator is controlled by an industrial SIEMENS S7 control system. AARS-P can be connected via software to the higher-level control system of an automatic packaging line, allowing its operation to be coordinated with conveyors, packaging machines, photocells and other equipment within the workstation.

Individual Integration into the Packaging Line

The frame height, working height, roll position, length of the applied sheet and method of communication with the higher-level control system are adapted to the specific application.

When designing the workstation, complete mechanical, electrical and software integration can be provided, including connection to an existing or newly designed conveyor line.

Areas of Application

• Building materials – covering pallets containing products sensitive to dust and weather conditions.
• Woodworking industry – protection of bundles, boards and panel products before dispatch.
• Logistics – automated packaging workstations handling different types of palletised loads.
• Manufacturing – protection of finished products before wrapping or further processing.

Key Benefits

• Fully automatic application of top-cover material
• Direct integration into the conveyor line
• Top-cover film, paper, Miralon foam or jute mesh
• Material width 700 – 1,300 mm
• Automatic pallet load height detection
• Precise length measurement using incremental sensors
• Pneumatic cutting system with a steel cutting disc
• Mechanical roll centring ± 50 mm
• Automatic detection of material run-out or tearing
• Adjustable unwinding speed up to 0.2 m/s
• SIEMENS S7 control system
• Optional second register for two different top-cover materials
• Individual mechanical, electrical and software integration

Technical Specifications

The specified parameters represent the standard configuration. The frame dimensions and working height are designed according to the layout of the packaging line.

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