CONE PAL is utilizing production equipment from Baumer hhs to help manufacture its pallets made from corrugated cardboard – a move thought to minimize cost, energy consumption, and waste.

Since CONE PAL was founded in 2020, it has established two machines for automated pallet production. The machinery features adhesive application units in the automated leg erector, which fold and glue die-cut, corrugated blanks to form the legs of the pallet.

These legs are then mounted on the top deck in a patented process. Each pallet can have six or nine legs, depending on its size, to cater to the pallet handling requirements of different industries. The size of the legs is not thought to impact the load-bearing capacity.

In spring 2022, CONE PAL collaborated with Baumer hhs; its HM-500 hot melt application technology and DLK go cold glue application head have resulted in a two-shot gluing process in the leg erection process. The gluing equipment is set to enhance flexibility when it comes to manufacturing different leg sizes, as well as ensure that the pallet and its legs are both stable and durable.

“We need practical equipment that functions reliably,” says Benjamin Sommer, general manager of CONE PAL GmbH & Co. KG. “That applies in particular to the adhesive application units in the leg erector, a component we also designed in-house. We had to resolve the issue of how to manufacture three legs of different sizes for the pallets in a fully automated process.

“The combination of hot melt and cold glue was customized to meet our specific needs, meaning it’s a perfect solution for us that promotes the cost-efficiency and sustainability of our products.”

The HM-500 and DLK go were also selected for their low cost, and the Xmelt melted and cold glue delivery unit are both utilized widely across Baumer hhs customers. They are also expected to apply the exact amount of glue required to secure the legs to prevent excess gluing and cut down on waste.

“As many as 15 years ago, my father recognized the potential advantages of pallets made of corrugated cardboard,” says Perry Sommer, managing partner of CONE PAL Vertriebsgesellschaft GmbH. “They are durable, 100% recyclable, nestable and reusable. What is more, they significantly cut costs along the supply chain for many applications.”

Reportedly, the pallets can carry heavy goods, such as beverages, and are adaptable to different consumer requirements; for example, they are compatible with printing and non-slip or additional water-resistant coatings. Currently, the CONE PAL product range features seven standard sizes, although the pallets can be manufactured in different sizes and shapes to help customers lower their transport and administrative costs.

Perry Sommer adds: “Our pallets can be stacked 40 high. They are also 3.5 cm lower and much lighter than conventional pallets made of wood or plastic.

“In other words, our customers save a lot of money on transport and reduce their environmental footprint. Fully loaded trucks carrying our pallets instead of wooden ones travel with 700 kg less weight for this reason alone.”

This development comes after Baumer hhs revealed a new application system for an anti-slip hot melt adhesive designed to secure transport and shipping boxes in transit without requiring additional plastic.

Additionally, Mondi provided its Advantage StretchWrap kraft paper to a range of pallet-wrapping applications last year. It worked with Robopac have joined forces to develop a paper stretch wrapping solution and replaced Silbo’s stretch film pallet wrapping with paper. Silbo also installed the first EW Technology PaperWrap machine at its Żory plant to offer flexible solutions to its customers.

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