The Challenge
Eliminating Manually Intensive Pallet Breakdowns in a High-Volume DC
Distribution center operators were overwhelmed by manual unloading of stacked cases from pallets. With labor shortages and high throughput expectations, the facility needed automation to:
- Extract full layers of cases—regardless of case dimensions or pallet configuration
- Handle up to 540 lb layers measuring 54″ × 54″
- Feed downstream conveyors with consistently oriented cases
- Maintain high throughput amid fluctuating incoming shipments
MWES was selected to design and integrate a flexible, high-capacity depalletizing solution tailored to the customer’s dynamic logistics needs.
The Solution
Layer-Gripper Depalletizer & Descrambler Cell with Layer Loading & Conveyor Integration
MWES delivered a turnkey automation system that uses a Schmalz vacuum layer depalletizer and custom Descrambling EOAT:
- Picks entire layers from full pallets—using vacuum-equipped layer gripper capable of handling 540 lb loads
- Transfers layers to an outfeed descrambling conveyor for de-stacking and case sorting
- Accommodates varying case sizes and pallet patterns with recipe-driven robot logic
- Integrates seamlessly with existing conveyor infrastructure and DC workflows
This solution enabled high-speed, hands-free handling of incoming pallets, preparing mixed-size cases for consistent downstream flow with minimal operator involvement.
The Results
High-Throughput, Reduced Labor & Reliable Continuous Operation
The MWES system delivered strong operational gains:
- Achieved an average layer pick rate of one layer per 15 seconds (≈ 4 layers per minute)
- Eliminated manual pallet breakdown labor in depalletizing operations
- Improved throughput consistency and reduced labor burden
- Scalable solution deployed across multiple distribution centers
By automating a traditionally labor-intensive and inconsistent process, the customer dramatically improved distribution center efficiency while reducing safety risks and labor demands.
