A finished appliance is a large, heavy, easily damaged unit. The interface between the line and the warehouse is usually a packing station, a palletiser and a transfer conveyor. If those three are not designed together, the warehouse receives a pallet that does not match the system record.
Key takeaways
- Define the handling unit before designing the conveyor: unit, carton, pallet or roll cage.
- Label at the point of packing, not at the warehouse.
- Pallet pattern and stack height must match the racking and the forklift.
- The WMS should receive the pallet ID at the moment the pallet is complete.
Define the handling unit
Most appliance factories ship cartons on pallets, but some ship units on roll cages or in containers. The handling unit determines the conveyor width, the transfer type and the labelling point. A conveyor designed for a carton will not handle a roll cage.
For cartons, the pallet pattern should be defined before the packing station is laid out. The pattern determines the carton orientation, the number per layer and the stack height. A pattern that is efficient on the pallet may be difficult to build by hand; check the ergonomics.
Packing and labelling
The carton should be sealed, labelled and scanned at the packing station. The label should include the model, serial number, pallet ID and destination. Scanning at the packing station ties the unit to the pallet before the pallet is built, which avoids a second scan at the warehouse.
Use a label printer at the line, not a central printer. A central printer adds a trip and a delay, and the label may be applied to the wrong carton.
| Stage | Data captured | Equipment |
|---|---|---|
| End of line test | Serial, test result | Test station |
| Packing | Carton ID, model, serial | Scanner, printer |
| Pallet build | Pallet ID, carton list | Scanner, palletiser |
| Stretch wrap | Pallet weight, dimensions | Scale, profile |
| Warehouse transfer | Location, status | WMS, forklift |
Conveyor and transfer
A roller conveyor is common for cartons and pallets. The roller pitch should support the carton without sagging, and the transfer gaps should be small enough that the carton does not catch. For heavy appliances, use a chain conveyor or a pallet conveyor with a positive drive.
The transfer from the line to the palletiser should be controlled. A carton that arrives too fast can jam the palletiser or fall off the conveyor. Use a accumulation zone before the palletiser and a slow-down section at the transfer.
Palletising
Manual palletising is common for large appliances, but it is heavy work. A vacuum lift or a collaborative robot can reduce the load. The palletiser should build the pattern from the bottom up and should not require the operator to climb the pallet.
If the pallet is stretch-wrapped, the wrap station should be after the pallet is complete and weighed. The weight and dimensions should be sent to the WMS with the pallet ID.
WMS integration
The WMS needs to know when a pallet is complete and where it is going. The handover should be a single transaction: pallet ID, carton list, weight, destination. If the WMS receives the cartons one by one, the pallet may be split or duplicated.
Define what happens when a carton fails at the packing station: it should be removed from the pallet record and routed to rework. A carton that is packed but not recorded is a lost unit.
Frequently asked questions
Should labelling happen at the line or the warehouse?
At the line, at the packing station. Labelling at the warehouse adds handling and increases the risk of a mismatch.
What conveyor is best for finished appliances?
A roller conveyor for cartons, or a chain/pallet conveyor for heavy units. The transfer gaps and the accumulation before the palletiser are the critical details.
How much accumulation is needed before palletising?
Enough to cover a pallet change or a wrap change, typically 10–20 cartons.
Send your packing pattern and warehouse layout to our engineers through the contact page; we will design the interface with the line.
