TopTier Palletizer Product

Guide
 Contents
1 Introduction
Purpose and Scope...........................................................1-1
Design Philosophy.............................................................1-1
Track Record ......................................................................1-2
Patents.................................................................................1-2
2 Safety
Fully Enclosed Palletizer Frames .....................................2-1
Light Curtain Protection ...................................................2-1
Redundant Fail Safe Hoist Protection.............................2-2
Touch-Safe Panel Design .................................................2-2
3 Controls
Control Components ..........................................................3-1
Color Touch Screen ...........................................................3-1
On-Screen Pattern Load Programming ..........................3-1
4 Models
Low Infeed ..........................................................................4-1
High Infeed ..........................................................................4-2
Oversized Loads .................................................................4-3
Pallet Jack Pallet Handling Models ................................4-4
Custom Solutions................................................................4-4
5 Loads
Product Requirements.......................................................5-1
Loads Built on a Pallet.......................................................5-3
Loads Built on a Slip Sheet...............................................5-3
Load Build Pallet-less........................................................5-3
Layer Load Weights ...........................................................5-3
Load Heights .......................................................................5-3
Restrictions .........................................................................5-4
6 Throughput Rates
7 Product Infeed Conveyor
Customer Upstream Conveyor .........................................7-1
Product Metering ...............................................................7-1
Product Turning..................................................................7-2
8 Row Build Conveyor
Electronic Gapping.............................................................8-1
Blade Stop Gapping ...........................................................8-1
9 Row Transfer Pushers and Pullers
VFD Controlled Row Pusher and Puller ..........................9-1
High-Speed Continuous Row Pusher..............................9-1
Pneumatic Row Pusher.....................................................9-2
Operations Guide
TopTier 2nd Ed. Rev. A
10 Layer Head
Layer Head Frame Construction ....................................10-1
Layer Head Operations....................................................10-1
Layer Head Capabilities ..................................................10-1
Roller Floor Construction ................................................10-3
11 Palletizer Frame
12 Concurrent Stretch Wrapping
13 Tie Sheet Dispenser
Standard Tie Sheet Dispenser .......................................13-1
Exterior Tie Sheet or Separator Dispenser ..................13-1
14 Slip Sheet or Pallet Liner Dispenser
Swing Arm Dispenser......................................................14-1
Shuttle Dispenser.............................................................14-1
Modified Tie Sheet Dispenser........................................14-1
15 Palletized Load Conveyor Systems
Strand Chain Conveyor....................................................15-1
Powered Roller Conveyor ...............................................15-1
Conveyor for Pallet-less Loads ......................................15-2
16 Pallet Dispensers
Fixed Size Dispenser for Side Pocket Pallets ..............16-1
Sliding Arm Pallet Dispenser for Wing Pallets ............16-1
Forklift Style Pallet Dispenser ........................................16-2
17 Layout Options
Low Infeed Standard Palletizer......................................17-2
High Infeed Standard and Internal Build......................17-2
Low & High Infeed with External Build .........................17-2
Accessory Footprints.......................................................17-3
18 Multi-Line Solutions
Legacy Multi-Line Solutions...........................................18-1
TopTier Multi-Line Solutions ..........................................18-2
19 Freight, Installation & Support
Freight ................................................................................19-1
Installation.........................................................................19-1
Post Sales Support...........................................................19-2
A1 Summary of Requirements
A2 Performance Guarantee
A3 Warranty
A4 Contact
 Introduction 1–1

 F I G U R E 1A

Purpose and Scope Improved palletizers were developed by TopTier to address shortcomings
in the options available for the automation of pallet loading. Legacy
palletizers had been characteristically bulky and expensive machines that
were difficult to program and inflexible to the changing requirements of
product and layer patterns. Robotic solutions continued to prove expensive,
with program adjustments typically performed by outside vendors.

Innovation from TopTier has achieved levels of performance never before

available at an affordable cost, creating a new standard in palletizing
automation. This Product Guide describes the advantages that separate
TopTier palletizers from legacy, robotic, and gantry palletizer systems.

Design Philosophy The members of the TopTier engineering team bring an extensive portfolio
of successful machine design for the material handling industry. Based
on the principal that simple solutions always work best, our palletizers
were developed using evolutionary patented improvements in technology.

Product Guide
2nd Ed. Rev. A TopTier
 1–2 Introduction

TopTier palletizers are designed to meet the following functional

requirements:
n Capable of handing virtually any load requirement,
including cases, bundles and bags
n Compact to accommodate restricted production areas
n Flexible modular design to accommodate multiple
layout requirements
n Easy to use, without need for outside support and maintenance
n Reliable performance under continuous operations in
harsh environments
n A full compliment of pallet loading accessories, including
stretch wrap and tie sheets
n Affordable entry cost with short-term cost justification
and low maintenance overhead

Track Record TopTier palletizers were introduced to the marketplace in 1998, and have
been field proven by leading Fortune 500 companies. Applications range
from low-speed substitution of manual operations to high-speed production,
and include a wide array of products in the food and beverage, health
care, commodities, and general manufacturing industries. After five years
of field success, TopTier has evolved into a leading supplier of palletizers
and accessories. A current list of TopTier customers and product
testimonials is available upon request.

Patents TopTier Palletizer designs are protected by several issued and pending
U.S. Patents.

Product Guide
TopTier 2nd Ed. Rev. A
 Safety 2–1

Safety is an overriding focus of TopTier engineering. The following features

are standard on all TopTier models.

Fully Enclosed All palletizers are fully enclosed in a Category Three safety cage (see
Palletizer Frames Figure 2A). Large doors on all sides allow easy access should a jam
occur or if maintenance access is required. Each door is protected by a
redundant contact that is continually monitored by a safety relay.

 FIGURE 2A  FIGURE 2B

Fully Enclosed Light Curtain Protection

Redundant contact sensors have two circuits. A safety relay constantly

monitors each sensor to confirm the functional status of the sensor. In
the condition of either sensor failure or a breach of the enclosure, the
safety relay cuts power to all drives. Pneumatic devices that retain
hazardous energy are purged when the safety circuit is engaged.

Light Curtain Pallet exit openings are protected by a muting light curtain (see Figure
Protection 2B). Should an operator break the curtain from the outside, the palletizer
will come to a complete stop to preclude injury. Even in the event that
an operator should trip and breach the light curtain at full speed, the
system will react before the falling operator encounters a moving device.

During normal operations, the light curtain functionality is muted and

allows a load to exit from inside the palletizer without shutting down
operations and negatively impacting rates. Muting is a sequenced event
where the load exiting must travel through sensors in a sequential manner
before the light curtain is disabled for load exit. The curtain is re-initialized
under PLC control and safety relay control when the load clears the
curtain.

Product Guide
2nd Ed. Rev. A TopTier
 2–2 Safety

Should the sequential events occur outside parameters or the load not
clear the exit within a preset time, the system will issue an alarm and
shut down the palletizer.

Redundant Fail Safe Palletizers are equipped with four-corner lift hoists to raise and lower the
Hoist Protection layer head without introducing cantilevered loading (see Figure 2C).
Some models raise and lower the row build conveyor or layer pre-build
table in the same manner. Each corner of the device being lifted is
connected to a lift chain with a length adjustor to compensate for differential
chain stretch. All chains are driven by separate sprockets, and the chains
are held against their sprocket by clamps to assure a chain cannot detach
from the drive sprocket. The sprockets are driven by a common drive
shaft connected to a drive that includes a fail-safe spring-applied brake
that engages when power to the motor is absent.

In addition to the fail-safe brake hoist safety system, spring-applied

latches are engaged whenever power to the drive removed. The latches
engage a serrated vertical guide used for each lift device.

 FIGURE 2C  FIGURE 2D

Redundant Safety Hoist Touch-Safe Panel

Touch-Safe TopTier provides an electrical panel utilizing touch-safe components (see

Panel Design Figure 2D). Touch-safe components significantly decrease the potential
for electrical shock should maintenance personnel need to access the
panel with electrical power connected. All control elements are 24 volt
DC.

Product Guide
TopTier 2nd Ed. Rev. A
 Controls 3–1

PALLET LAYERS 4 CURRENT

HEAD EMPTY PATTERN
12-PACK CASE
LAYER BUILD BOXES 4
ROW BUILD BOXES 7 ADJUST
TURN AREA BOXES 1 COUNT

SYSTEM RUNNING
PURGE
PART SHOW MANUAL SCREEN
PALLET ALARMS SELECT SELECT

Control Components Standard TopTier controls provide functionality and ease of use far
superior to any other palletizer solution. The summary below provides
an introduction of the standard control capabilities built into every TopTier
palletizer. Consult the TopTier Operations Guide for a complete description
of palletizer programming and controls.

Allen Bradley control elements are used throughout TopTier palletizers.

The standard PLC is Allen Bradley CompactLogix, with optional alternatives
available. EuroDrive VFDs are used exclusively for hoisting applications
and standard for all other applications. TopTier uses VFDs on many
drives to allow controlled acceleration and deceleration to achieve
increased machine longevity, accurate positioning control and gentle
product handling.

Color Touch Screen All TopTier palletizers are equipped with a color touch screen control
interface. Interface screens provide dozens of functions including manual
control of all devices, simple case count adjustment, alarm messages
with corrective actions, timer adjustments, system purge and all other
functions required to configure or adjust palletizer operations. Access to
functional operations through the screen interface is comprehensive, with
no requirement to access the underlying PLC code.

On-Screen Pattern Layer patterns are created using the touch screen interface. Any pattern
Load Programming can be added in a few minutes using exclusive EasyStack™ layer
programming software. EasyStack includes sophisticated functions such

Product Guide
2nd Ed. Rev. A TopTier
 3–2 Controls

as labels-out, tie sheet insertion levels, special pallet stretch wrap

sequence, and pattern build gap requirements. Each pattern menu
instruction is unique to up to 50 patterns. A global pattern menu is not
required.

Fifty Load Palletizer controllers store up to fifty separate patterns. Each pattern can
Patterns Standard be named with a customer selected alphanumeric name consisting of up
to 16 symbols. Standard SKU numbers or other pattern names are used
to simplify operator selection of new patterns. Programmed patterns are
easily selected from a scroll down list for instantaneous load pattern
change.

Each load pattern menu offers 1 to 40 cases per layer standard, with
additional case capability optionally available. Standard programming
features include: number of layers per load, load interlocking, column
stacking and combination column/interlocking loads.

On-Screen Adjustments The copy and paste pattern menu feature allows easy creation of new
and Alarms patterns by using another menu as a template. New menus that are
closely similar to an existing pattern menu can be added quickly without
inputting redundant data.

The most common operational fault encountered with any palletizer

operation involves cases entering the system out of sequence. In such
an event, an alarm message will occur with the interface screen displaying
possible corrective actions. The operator simply adjusts case count at
the touch screen and automatic operations are resumed. Generally, case
jams or miscounts are remedied in seconds. Non-critical alarms such as
"PALLET DISPENSER LOW" will display while automatic operations
continue. Alarms that require immediate attention will stop the palletizer

Product Guide
TopTier 2nd Ed. Rev. A
 Models 4–1

Low-Infeed

TT-L10/TT-L20
Standard Low-Infeed

FIGURE 4A
TT-L10/L20

Low-Infeed palletizers accommodate existing low level conveyor and

are typically used for replacement of manual palletizing operations. Low-
Infeed palletizers build rows at the infeed elevation and transports each
row to the layer deposit level.

n Infeed from 12" to 72"

n 115" x 80" footprint
n Multiple infeed and pallet exit options
n Finished pallet to 80" tall; optional to 108"

Layers are built on the layer head and then delivered to the pallet (see
Figure 4A).

TT-L50
Low-Infeed with
Layer Pre-build Table

FIGURE 4B
TT-L50
Concurrently built layers on a pre-build table are transported to the level
of the layer head and swept onto the layer head (see Figure 4B).

Product Guide
2nd Ed. Rev. A TopTier
 4–2 Models

High-Infeed
TT-H10/TT-H20
Standard High-Infeed

FIGURE 4C
TT-H10/H20

High-Infeed palletizers are used when the case infeed level is above the
tallest finished load. TopTier High-Infeed palletizers lower layers to the
load so the pallet remains stationary during load build.

n Infeed from 72" to 144" standard for short pallets; infeed

can be 6" above finished pallet height
n Multiple infeed and pallet exit options
n Finished pallet to 108" tall

Layers are built on the layer head and then delivered to the pallet (see
Figure 4C).

TT-H50e
High-Infeed with
External Layer
Pre-Build Table

FIGURE 4D
TT-H50e

The external pre-build table allows concurrent layer build operations and
layer conditioning and deposit operations for higher throughput rates
(see Figure 4D).

n High-speed operation
n 80" x 120" footprint

Product Guide
TopTier 2nd Ed. Rev. A
 Models
4–3

TT-H50i
High-Infeed with
Internal Layer
Pre-Build

FIGURE 4E
TT-H50i

A layer is constructed on the internal pre-build table and transferred to

a standard layer head nested below the pre-build table. While the layer
head transports and conditions the layer for deposit, layer construction
continues on the internal pre-build table (see Figure 4E).

n High speed operation

n 80" x 80" footprint

Oversized Loads Options are available to handle higher loads and wider layers. All models
are capable of handling loads up to 110" in height and layer widths of up
to 60" x 60" (see Figure 4F).

FIGURE 4F
Oversized Loads

Product Guide
2nd Ed. Rev. A TopTier
 4–4 Models

Pallet Jack Pallet Low and High-Infeed models operating at lower throughput rates are
Handling Models available with pallet jack pallet handling (see Figure 4G). Empty pallets
are positioned by the operator, and the operator removes full pallets with
a pallet jack. Due to increased pallet change out time, rates of less than
a layer every 90 seconds apply.

FIGURE 4G
Pallet Jack Pallet Handling

Custom Solutions Special requirements are accommodated by making modifications to

standard components. Modular design allows cost-effective customization
with no sacrifice to performance and reliability (see Figures 4H & 4I).

All TopTier palletizers are available in

stainless steel. Suitable for non-caustic
wash down or other special environments.

FIGURE 4H
Stainless

Product Guide
TopTier 2nd Ed. Rev. A
 Loads 5–1

FIGURE 5A
Cases
Product Requirements TopTier palletizers are capable of building nearly any load on pallets,
pallet-less or other industry requirement.

Cases Corrugated cases and trays with and without overwrap are the most
common application (see Figure 5A).

Standard Requirements
Width and Depth Weight
Minimum: 6" x 6" Standard Minimum: 3 lbs
Maximum: Standard Maximum: 50 lbs
Case Turning: 27" Diagonal Layer Load
No Case Turning: 28" x 50" Standard: 300 lbs
Height Maximum: 1000 lbs
Standard Minimum: 2" Layer Dimensions
Standard Maximum: 18" Standard Maximum: 50" x 50"

Special Conditions

n Product heights of less than 2" or greater than 18" require

engineering review
n Product weights of less than 3 lbs or greater than 50 pounds
require engineering review

Oversized Loads

n Oversized layer loads of up to 60" x 60" require

engineering review
n Diagonal limitation for product is 37" for turned cases
n Maximum non-turned case dimension is 38" x 60"
n Maximum layer weight is 600 pounds for machines designed to
handle oversized loads

Product Guide
2nd Ed. Rev. A TopTier
 5–2 Loads

Overwrapped Bundles must be tight to the product and without film tails (see
Bundles
Figure 5B).

FIGURE 5B
Overwrapped Bundles

Bags Palletizers have limited bag handling capabilities. Bags that are firm with
limited product flow inside the bag can be handled effectively. Generally
infeed conveyor, turning, and row pusher devices must be configured for
a specific bag. Engineering review of actual product is required prior to
quoting.

Buckets, Due to the consistency of layer set down accuracy, palletizers effectively
Pails, and
Nested Containers handle totes, trays and buckets that nest when stacking (see Figures
5C & 5D). Engineering review of actual product is required prior to quoting.

FIGURE 5C FIGURE 5D
Buckets Nested Tablock Containers

Product Guide
TopTier 2nd Ed. Rev. A
 Loads
5–3

Loads Built on a Pallet Loads can be built on pallets of various sizes including CHEP or GMA.
Wing pallets or pallets without bottom runners may require special pallet
conveyor.

Loads Built on a Loads can be built on slip sheets with or without pallets. Pallet-less loads
Slip Sheet require close-centered pallet roller conveyor, mesh conveyor or belt
conveyor.

Loads Built Pallet-less Loads built without a pallet or slip sheet can be built on a turntable and
concurrently stretch wrapped, with exit on standard conveyor. Loads built
without a pallet that are not concurrently stretch wrapped must be built
on a moving floor conveyor such as slat or wire mesh conveyor.

Layer Load Weights The palletizers build layers on a layer head, with the load deposited at
a stationary load build position. Consequently, total load weight generally
does not impact palletizer performance.
n Layer weights of 300 pounds are standard.
n Layer weights from 300 pounds to 500 pounds require increased
hoist drive sizing.
n Layers weights from 500 pounds to 1000 pounds require increased
hoist drive sizing and close centered rollers on the layer head.
n Machines designed to handle oversized layers are generally limited
to 600 pound layer weights.

Load Heights The palletizers are designed to build loads to any customer requirement.
Low-Infeed machines require frame extensions to accommodate loads
taller than standard. The cost of modification is modest and the finished
machine ships as upper and lower sections inside a standard dry van.
Maximum Standard Height
n Low or High-Infeed palletizers with pallet jack pallet handling,
including the pallet: 84"
n Low or High-Infeed palletizer equipped with a stretch wrapper
or pallet conveyor, including the pallet: 72"
Maximum Special Height
n Both Low or High-Infeed palletizers can be equipped with a
frame extension and build loads to 110" (see Figure 5E).

Product Guide
2nd Ed. Rev. A TopTier
 5–4 Loads

FIGURE 5E
Overheight Load (110")

Restrictions The palletizers are designed to offer the flexibility of handling a wide
variety products. Product consistency is critical to the successful operation
of the palletizer. Deficiencies that will impact operation include:
n Cases erected improperly to create parallelograms can impact
case turning and finished layer quality.
n Improper taping resulting in two cases joined or attached
entering together, or a tape tail that can become stuck on
rollers will often cause miss-counts or jams.
n Case bottoms that are not flat are difficult to rotate at a case
turner due to inconsistent contact with the conveyor roller surface.
n The palletizer can accommodate case tops with a slight bulge.
Open flaps or excessive bulging can create problems when the
next layer is deposited.

TopTier requires representative product to be delivered to our plant for

pre-shipment testing for most orders placed. The resolution of product
handling characteristics is critical in achieving successful installations.
Should pre-order discussions indicate potential product handling issues,
TopTier may request samples prior to quoting.

Product Guide
TopTier 2nd Ed. Rev. A
 Throughput Rates 6–1

Palletizer throughput rates are subject to several considerations. The

pattern of each layer is the primary factor in determining ultimate throughput
rates. The total numbers of layers per load and the row push direction
also influence rates. TopTier engineering performs an analysis each layer
pattern in order to generate the highest possible throughput rates. Efficient
layer patterns begin with the construction of efficient rows. Rates are
often significantly impacted by the row push direction. Some patterns are
efficiently built pushing 40" rows and others benefit from pushing 48"
rows for a typical 40" x 48" pallet pattern. Final determination of anticipated
throughput rates can are confirmed after engineering review of layout
and pallet patterns.

Following are general guidelines of palletizer throughput rates. Rates are

not impacted by the number of cases per row.

TT-L10
Standard Low-Infeed Model
Generally 2 to 5 rows per minute are achieved (1-15 CPM)

TT-L20
Low-Infeed Model with High-Speed Lifts
Generally 4 to 6 rows per minute are achieved (10 to 20 CPM)

TT-L25
Low-Infeed Model with External Row Build
A row is constructed external to the palletizer requiring additional floor
space. Because row build is concurrent with row transport and push,
throughput is increased. Generally 5 to 8 rows per minute are achieved
(10 to 25 CPM). Total throughput is usually less than two layers per
minute.

TT-L50
Low-Infeed Model with Layer Pre-Build
Layer pre-build palletizers build a full layer concurrent with layer
conditioning and layer deposit. High-speed row pushers reduce the
impact of the number of rows per layer. Generally rates are 2 to 4
layers per minute (20 to 50 CPM).

Product Guide
2nd Ed. Rev. A TopTier
 6–2 Throughput Rates

TT-H10
Standard High-Infeed Model
Because vertical row transport is not required when building layers,
rates are higher than Low-Infeed palletizers. Rates are generally 8
pushes (2 layers) per minute.

TT-H50e
High-Infeed Model with External Layer Pre-Build
Rates are generally 2 to 4 layers per minute.

TT-H50i
High-Infeed Model with Internal Layer Pre-Build
Rates are generally 2 to 4 layers per minute.

Product Guide
TopTier 2nd Ed. Rev. A
 Product Infeed Conveyor 7–1

Due to the variety of products handled, TopTier offers several standard

product infeed systems. Two subsystems make up the palletizer infeed:
product metering and product turning. Upstream customer conveyor must
be considered in many applications.

Customer Upstream Palletizers are often located immediately downstream of a taper or product
Conveyor sealer. Due to the inherent surging of palletizer operations caused by the
stop and start motions of the meter system feeding the product turner,
some gravity conveyor between the product metering system and customer
equipment is recommended when rates exceed 8 CPM. Faster systems
equipped with a pre-build table require at least 5 feet of gravity conveyor
upstream of the metering conveyor.

To avoid overrunning the metering system, TopTier recommends that

customer powered conveyor located immediately upstream of the palletizer
be automatically stopped should product begin to accumulate, and
automatically restarted once the accumulation is relieved. TopTier provides
engineering recommendations for customer supplied downstream conveyor
on faster systems.

Product Infeed Products entering the meter belt that are turned by a product bump turner
Location
must enter registered against the guardrail side of the infeed system that
the product turner is on. If products are not positioned against the turner
side, the product can miss the bump turner and enter the palletizer without
turning which will cause a jam or incorrect layer pattern.

Products entering the meter belt that are turned by a lift and rotate device
or differential drive system need to enter on the centerline of the infeed
conveyor system. Product must be prevented from entering the system
two abreast or turned 90 degrees from normal.

Product Metering The standard metering system is a dual meter belt (see Figure 7A).
The rough top belt section runs slower than the second conveyor. The
high friction surface of the first belt restrains products accumulated
upstream.

The second belt runs at product turning speed and pulls a gap through
the differential speed of the two belts for product counting. Standard
speed on the product turning section is 180 FPM.

Product Guide
2nd Ed. Rev. A TopTier
 7–2 Product Infeed Conveyor

FIGURE 7A
Dual Metering Belt

Product Turning Layer building requires product turning. Due to the variety of products
handled, several turners are available.

Bump Turner The vast majority of products are turned by a bump turner. Products that
travel straight do not hit the turn blade. Those that require turning hit the
turner face and a combination of inertia and conveyor drive causes the
product to rotate 90 degrees around the turner blade. The turner blade
has cushioning either through an air cylinder or springs. Products
inappropriate for the bump turning method include:
n Long narrow products
n Products with a diagonal dimension in excess of 24"
n Very small or very heavy products

Bump Turn Some long products require an assist to turn around a bump turner (see
and Assist
Figure 7B). An assist cylinder extends when the product hits the turn
blade and helps start the turn process by pushing the rear of the product.
Conveyor drive and inertia completes the product turn cycle.

FIGURE 7B
Bump Turn & Assist

Product Guide
TopTier 2nd Ed. Rev. A
 Product Infeed Conveyor
7–3

Lift and Rotate A lift and rotate device raises the product off the conveyor, rotates the
product 90 degrees and lowers the product down to the conveyor (see
Figure 7C). The device is generally used for products with a diagonal
dimension above 24". Lift and rotate devices are also used for soft bottom
products where roller drive does not provide reliable turning. Rates are
less than 15 CPM.

FIGURE 7C
Lift & Rotate

Lift and Rotate Lift and rotate devices can be equipped with enhanced controls to rotate
with Labels Out products 90 degrees right, left or 180 degrees to achieve programmed
labels-out finished pallets (see Figure 7D). Labels-out programming
is a standard feature of TopTier's EasyStack™ software provided with
each palletizer. Rates are less than 15 CPM.

FIGURE 7D
Lift & Rotate Labels Out
Differential Differential drive consists of two belts that run under product in a product
Drive turning section of the infeed conveyor. If the product requires turning,
one belt slows down which causes the faster belt to swing one side of
the product and causes the product to turn 90 degrees. The motion is
similar to the turning method of a tracked vehicle such as a tank.

The system is appropriate for larger flat-bottomed products running at

high rates. Because motion is continuous, more product can be inducted
through the product turner than a lift and rotate or bump turner. Differential
drive speeds are unique for each pattern menu allowing instant product
changes without manually adjusting speeds after initial setup.

Product Guide
2nd Ed. Rev. A TopTier
 7–4 Product Infeed Conveyor

Right Angle Right angle infeeds are used only when dictated by layout constraints
Product Turning
Infeed (see Figure7E). When a product enters the palletizer in the same
orientation as it enters the meter belt, product rotates around a turning
post. If change of orientation is required, product feeds onto a right angle
transfer.

FIGURE 7E
Right Angle Product Turning Infeed

Special Infeed Layout constraints sometimes require special equipment to achieve an

Systems
effective palletizing solution. Pullers are sometimes used to pull a product
onto the palletizer infeed when space is not available for a curve. This
method is suitable only for low throughput rates.

Sequenced multiple bump turners are used to achieve labels-out if rates

exceed the capability of a lift and rotate device. Infeed length must be
increased a minimum of 10' and the system is unsuitable for some
products.

FIGURE 7F FIGURE 7G
Case Puller High-speed Labels-out Case Rotator

Product Guide
TopTier 2nd Ed. Rev. A
 Row Build Conveyor 8–1

Standard palletizers construct rows for transfer to the layer head or layer
pre-build table on the row build conveyor. 1.9" roller conveyor with centers
of 3" are typical. 2" centers are used with case dimensions less than 9".
For case dimensions less than 6", 1 3/8" rollers are provided on 1 1/2"
centers. Bags or products not suited for roller conveyor applications
require plastic chain or slick top fabric belt conveyors.

Electronic Gapping Electronic gapping capability is standard on all palletizers (see Figure
8A). Gap distance configuration is a standard feature of EasyStack™
software, and allows each pattern to have separate row build gapping
instructions. Gapping is achieved with precise VFD control of the row
build conveyor speed. VFD control contributes less wear to the equipment
because rollers do not continue to drive under a stopped product and
because product does not collide abruptly against a row stop.

Electronically Gapped Product on a Layer Head

FIGURE 8A
Product Gapping

Blade Stop Gapping Traditional blade row stops are available as a special requirement. Due
to the increased abuse of the row build conveyor and abruptness of
product stops, blade stops are seldom employed. Special requirements
include inconsistencies in the bottom surface of the product that prevent
accurate electronic gapping.

Product Guide
2nd Ed. Rev. A TopTier
 9–1 Row Transfer Pushers and Pullers

Methods of transferring constructed rows to the layer head are based on

the product handled and rates required. TopTier has several technologies
available.

VFD Controlled Row The standard row transfer device from TopTier is a reciprocating row
Pusher and Puller pusher or puller (see Figure 9A). Row pushers are used on all
palletizers except Low-Infeed palletizers without a pre-build table (TT-
L10/TT-L20). Models TT-L10/TT-L20 transfer rows with a puller. Row
pullers are used on all models. Palletizers with external pre-build tables
utilize both a row pusher, and a layer puller.

FIGURE 9A
Row Pusher & Puller

All pushers and pullers have wide flat-faced surface that contacts the
product to distribute the contact surface load and minimize potential
damage. Movement is by controlled acceleration and deceleration VFD,
and achieves gentle product handling.

Due to the ability to control the motion precisely, the reciprocating motion
of the device is nearly as fast as a continuous pusher. Rates are generally
not impacted by use of the standard design.

High-Speed Continuous Extremely fast applications sometimes require use of a continuous row
Row Pusher pusher (see Figure 9B). The device mounts over the row build conveyor
in a separate safety enclosure. Two chain loops support a continuous
motion pusher bar that pushes the row and returns over the top allowing
continual case infeed. By eliminating the retracting stroke characteristic
of the standard pusher, continuous pushers are faster in some applications.

Product Guide
TopTier 2nd Ed. Rev. A
 Row Transfer Pushers and Pullers
9–2

 FIGURE 9B

Continuous Row Pusher

Continuous pusher devices are disadvantaged by the smaller contact

surface of the pusher bar. The combination of small contact surface and
rapid motion increases the potential for damage to the product. Continuous
pushers are not employed on delicate product or product on which case
marking is unacceptable.

Pneumatic Row Pusher Special handling requirements can be accommodated by a pneumatically

operated pusher (see Figure 9C). Generally the pusher motion is less
consistent. Pneumatic pushers are appropriate for low throughput
applications only.

 FIGURE 9C
Pneumatic Row Pusher

Product Guide
2nd Ed. Rev. A TopTier
 10–1 Layer Head

TopTier uses a layer head to build, condition and transport layers for
deposit onto an empty pallet or previously deposited layer. Our universal
layer head is used for all models including High-Infeed palletizers. TopTier
High-Infeed machines build the layer at the infeed level and lower the
layer on the layer head for deposit on the pallet. The following features
and benefits demonstrate the innovations of TopTier's layer head design.

Layer Head Frame The layer head frame is a precision laser cut and formed weldment that
Construction is designed to support a 1,000 pound layer standard (see Figure
10A). Each corner is supported by a hoist chain that is attached with an
adjustable connector to compensate for chain stretch. The resulting non-
cantilevered system is guided by oil impregnated nylon vertical travel
guides.

 FIGURE 10A  FIGURE 10B

Layer head Frame Weldment Layer Head Conditioning Load

Layer Head The simplicity of the layer head operation is apparent upon viewing one
Operations layer deposit cycle. After a layer is constructed of rows, the layer is
conditioned on four sides and the roller floor retracts into the vertical "L"
of the layer head. The conditioned layer is then deposited through the
open layer head floor (see Figures 10B-10D). Palletizer operations
are available for viewing on video by accessing the TopTier web site
through the navigation tab on the left side of this page.

Layer Head Despite the simplicity of the layer head system, just about any palletizing
Capabilities application can be handled effectively.

Layer Size The layer head allows finished loads to 50" square. Machines designed
to handle oversized loads are available with an opening of 60" square.

Product Guide
TopTier 2nd Ed. Rev. A
 Layer Head
10–2

Layer Build A standard layer head can receive 40" or 48" rows for a standard GMA
Direction
pallet load in standard configuration. The ability to build a load with either
row length increases layout flexibility and allows layers to be built at
higher speeds.

Layer Build with Layer heads are equipped with 'wings' on both sides of the roller floor
Gap Patterns that creates a 63" wide row length limit. Thus, gap patterns can be spread
out over the available 63" space if required. The wings allow a large layer
build area and minimizes the support roller floor tube length for increased
strength to the net size of the floor opening.

Layer All layer heads are equipped with four-sided layer conditioning (see
Conditioning
Figure 10E). Two sides are compressed by centering clamps that always
center the load over the floor opening down to 32". Center clamping is
pneumatic allowing air pressure adjustment to control clamping force.

 FIGURE 10E

Layer Head

One side of the layer is compressed against the layer head backstop by
the retracting of the roller floor in combination with layer back-clamp
compression.

The layer head back-clamp function is achieved with the row puller on
slower speed Low-Infeed machines. The VFD that controls the puller
transitions into Torque Control Mode when clamping, allowing menu-
based clamp force adjustment. High-Infeed or Low-Infeed high-speed
palletizer layer heads are equipped with a pneumatic-actuated submerged
roller that rotates up and compresses the layer on the fourth side.

Both back clamp systems can travel to within 32" of the layer head
backstop. When combined with 32" side clamping capability of the
centering clamps, the clamp systems provides four-side layer conditioning
for any load down to 32" square.

Product Guide
2nd Ed. Rev. A TopTier
 10–3 Layer Head

Load Positioning The layer head backstop is registered to one edge of the pallet. If several
Relative to the Pallet
loads sizes are handled, an adjustable backstop is available to position
the load inside the pallet dimensions on all sides, equally overhanging
the pallet dimensions or any combination required.

Layer Pattern Essentially any pattern can be built provided the finished layer size is
Flexibility less than the opening of the layer head. Maintaining cases at each corner
of a layer and spreading gapped cases along any side of the finished
layer is a standard capability.

Roller Floor The design of the roller floor provides several advantages compared to
Construction legacy solutions (see Figure 10F). Roller support tubes have the ability
to rotate, providing less resistance to pushed rows. The advantages of
a roller surface are most significant when the last row is pushed. During
advancement of the final row, all previously assembled rows are pushed
as well. On a static platform, the significantly larger force required increases
the likelihood of product damage. TopTier's roller floor innovation prevents
such potential damage.

 FIGURE 10F

Roller Floor Construction

Product Guide
TopTier 2nd Ed. Rev. A
 Layer Head
10–4

Other features and benefits include:

n Rollers are strong 1" diameter .120" wall tubes supported at each
end by extended chain pins.
n The hardened chain pins have ½" diameter axles pressed onto
them. Pin length and roller tube bushings are over 1" long. Each
tube is amply supported and the tubes rotate on lubricated bushings.
n The parallel chain loops are driven by large sprockets with 180
degree chain wrap.
n Idlers guide the chain loop in an 'L' shape and one idler on each
side provides chain take-up.
n Sensors at each end of travel in conjunction with tooth counters
allow the PLC to accurately register the floor position.
n The motor is VFD controlled for fluid acceleration and deceleration.
VFD control also allows manipulation of roller floor pullout speed
and centering clamp sequences for special layer patterns.

Standard roller floor centers are 2 1/2", handling product with a minimum
dimension greater than 9". Standard floors handle layer weights up to
500 pounds.

Lighter layers with very small products or non-uniform bottom products

such as bags require close centered roller floors. Close centered floors
are equipped with a roller floor on 1 1/4" centers. The close centers allow
layer weights to 1000 pounds.

The versatility of the layer head allows stacking techniques generally not
available from legacy palletizers. Due to the precise control of roller floor
motions through VFD drive and tooth counter combined with manipulation
of center clamping motions, layer gaps can be retained on any side of
the layer.

Product Guide
2nd Ed. Rev. A TopTier
 10–5 Layer Head

Special Roller TopTier palletizers also have the ability to stack freezer loads with uniform
Floor Capabilities
gaps around all products. Agriculture or industrial plastic containers with
mating interlocking tops and bottoms can also be stacked due to precise
repeatability of the layer conditioning and layer deposit technology (see
Figures 10G-10H).

 FIGURE 10G 1" gap around each case allows

Fold Flat Agriculture Trays proper air circulation

 FIGURE 10H

Product Gapping

Product Guide
TopTier 2nd Ed. Rev. A
 Palletizer Frame 11–1

TopTier palletizers are designed in 3D CAD Solids and manufactured

using the latest laser cut and CNC forming technologies. All frame
members are a minimum of ¼" formed mild steel with 8" x 8" corner
members (see Figures 11A-11B).

Bolted side plate in position with strong

moment connection due to flush mount.
All corners are smooth radiuses.

 FIGURE 11A  FIGURE 11B

Frame Construction Frame Corners

Models share common components allowing increased economies to be

passed on to end users. By constructing the palletizers from formed steel,
conversion to stainless steel is straightforward and cost-efficient.

Each welded side and base assembly is powder coated. Final assembly
consists of bolting end frames into position and connecting the base
frame with welds and bolt connectors. The resulting welded box frame
is rigid, square and extremely strong. Base frame assemblies include
forklift pockets to allow easy transport and positioning on the production
floor during installation (see Figure 11C).

Base frame with fork pockets bolted and

welded to palletizer sides

 FIGURE 11C

Forklift Pockets

Product Guide
2nd Ed. Rev. A TopTier
 12–1 Internal Concurrent Stretch Wrapping

All TopTier palletizers are available with concurrent stretch wrapping (see
Figures 12A-12B), with the exception of models with external pre-
build tables. Because the palletizer continues to build layers on the layer
head during the wrap process, rates are not impacted by stretch wrapper
operations. The load is progressively wrapped as the load is built.

 FIGURE 12A  FIGURE 12B

Stretch Wrapping Internal Concurrent Stretch Wrapper

After the final layer of the load is deposited only this top layer requires
wrapping. Film is cut at the top of the load, so pallet change out is nearly
as fast as non-wrapped loads.

Stretch Wrapper
Features
Turntable Turntables are mounted on heavy duty ring bearings integrated into a
Construction
standard frame base (see Figure 12C). Electrical & pneumatic rotary
unions provide utility connection to the turntable deck. Roller conveyor
is provided as standard turntable deck. Special decks for pallet-less loads
are also available. Rotation is controlled by a VFD drive with tooth counter
positioning. Standard load capacity is 2,500 pounds with heavier weights
optional.

 FIGURE 12C
Turntable Frame

Product Guide
TopTier 2nd Ed. Rev. A
 Internal Concurrent Stretch Wrapping
12–2

Stretch Wrapper The stretch wrap head is mounted on a vertical guidepost that is mounted
Construction
in an enclosure connected to one side of the palletizer. The stretch
wrapper enclosure becomes an integrated part of the palletizer enclosure
and maintains Category Three safety protection (see Figure 12D).
The wrap head is raised and lowered by a VFD controlled drive with
position counter.

 FIGURE 12D

Stretch Wrapper Construction

Stretch Wrapper The integration of stretch wrapping and palletizing controls is

Controls
comprehensive. All film handling, cutting and end treatment functions are
automatic, and are controlled from the interface screen. Wrapping
sequence can be part of the layer pattern menu allowing separate wrap
sequences for each load. Other features include:
n variable number of base and top wraps
n variable wrap density and over wrap
n fixed or variable film tension
n components manually cycled from the control interface
n film brake and other alarms with diagnostics standard

Film Film heads are set for 250% pre-stretch. Good quality film of 80ml
Specifications
thickness is required. If other film pre-stretch is required or thinner film
is used in existing operations, a sample roll must be provided for testing.
20" film rolls are standard.

Product Guide
2nd Ed. Rev. A TopTier
 13–1 Tie Sheet Dispenser

Standard Tie The standard tie sheet dispenser uses a telescoping arm to pick and
Sheet Dispenser place a sheet onto the load. Each load build menu can have distinct sheet
insertion instructions. Both vertical and horizontal motions of the dispenser
are electric with VFD control. Sheets are picked with vacuum cups. All
devices can be manually cycled from the touch screen interface. If sheet
sizes change with loads, the dispenser magazine can be set with adjustable
guides (see Figure 13A).

 FIGURE 13B

Tie Sheet Dispenser

Exterior Tie Sheet or In the case that 'egg crate' style separators are required for air circulation,
Separator Dispenser an external dispenser is installed on one side of the palletizer (see
Figure 13B). The system allows a gripper system to be used suitable for
the difficult-to-handle separator sheets. The same device can be used
for standard tie sheets if the palletizer builds both load styles.

If a separator sheet is required, the load under construction shuttles to

the dispenser location while the next layer is constructed on the layer
head. Due to the need to shuttle the load between two positions, layer
construction time cannot be less than approximately 45 seconds.
Concurrent stretch wrapping is not available due to the shuttle time
requirements.

 FIGURE 13B

External Tie Sheet Dispenser

Product Guide
TopTier 2nd Ed. Rev. A
 Slip Sheet or Pallet Liner Dispenser 14–1

Slip sheets can be used as pallet liners that are smaller than the pallet
or as slip sheets that overhang the pallet. When the same material is
used for both pallet liners and tie or layer sheets, a tie sheet dispenser
can handle both requirements. Otherwise, three tie sheet dispenser
options are available.

Swing Arm Swing arm dispensers are positioned between a pallet dispenser and
Dispenser the palletizer (see Figure 14A). Swing arm dispensers require an
extended infeed conveyor. The device is simple and inexpensive.

FIGURE 14A
 FIGURE 14B
Swing Arm Dispenser Shuttle Dispenser

Shuttle Dispenser Shuttle dispensers place a sheet on the pallet after the pallet is positioned
for loading (see Figure 14B). The same design is often used for pallet-
less loads. The sheet pick head shuttles between the pick position and
set-down position inside the palletizer. The device requires little space
outside the basic palletizer footprint.

Modified Tie If layout requirements do not allow use of the shuttle dispenser or swing
Sheet Dispenser arm dispenser, our standard tie sheet dispenser can be used. To achieve
cost savings, the vertical motion of the dispenser is operated by pneumatic
lift rather than VFD electric system.

Product Guide
2nd Ed. Rev. A TopTier
 15–1 Palletized Load Conveyor Systems

The diversity of load support systems handled requires several conveyor

options. The bottom board configuration of a pallet or the lack of pallet
must be considered when specifying exit conveyors.

Strand Chain Chain conveyor features #50 chain supported by key stock contacting
Conveyor the chain roller to provide roller support of the load (see Figures 15A
- 15C). Center drives have 90 degree wrap and include ample chain take-
up. Frames are heavy ¼" material. Optional VFD drives are available for
gentle load handling. Pallet jack accessible low profile conveyor with
access ramps is available. Standard design accommodates 2,500 pound
total load weights. Additional load weight capabilities are available.

 FIGURE 15C  FIGURE 15A  FIGURE 15B

Pallet Jack Accessable Pallet Conveyor Two-strand Chain Conveyor Three-strand Chain Conveyor

Powered Roller Powered roller conveyor has the same frame and capacity as chain
Conveyor conveyor (see Figures 15D & 15E). Powered roller conveyors are
equipped with 2 7/8" diameter rollers with .90 wall. Through shafts are
supported by sealed bearings at each end. The chain-to-chain drive is
#40 and the chain guard is mounted flush with top of roller for access
from either side. Conveyor is available with rollers installed at either 3"
or 6" on center.

 FIGURE 15D FIGURE 15E



Powered Roller Conveyor – 3" Centers Powered Roller Conveyor – 6" Centers

Product Guide
TopTier 2nd Ed. Rev. A
 Palletized Load Conveyor Systems
15–2

Conveyor for Roller conveyor, wire mesh conveyor and belt conveyor are available for
Pallet-less Loads pallet-less loads (see Figures 15F & 15G). Roller conveyor is equipped
with 3" roller centers. Turntables are available for right angle transfer
requirements.

Concurrent stretch wrapping is available. Wrapped loads without a slip

sheet or pallet are effectively handled when concurrently wrapped.

 FIGURE 15F  FIGURE 15G

Wire Mesh Conveyor Slip Sheet on Belt Conveyor

Product Guide
2nd Ed. Rev. A TopTier
 16–1 Pallet Dispensers

Three models are available to provide pallet dispensing solutions for any
pallet design. All dispensers are rated for 600 pound pallet stacks. TopTier
pallet dispensers lift and separate pallets; drag-from-the-bottom designs
are characteristic of poor reliability and are not offered. Heavier stack
weight capacities are available.

Fixed Size Dispenser for The standard dispenser is used for 40" x 48" pallets (see Figure 16A).
Side Pocket Pallets Pallets can be loaded with the forklift accessing either the 40" or 48" side,
allowing empty pallets to be loaded in either orientation. Loaded pallets
exit the palletizer from all directions except from the pallet load side.

The dispenser is a lift and separate design where the entire stack is raised
above the bottom pallet allowing the empty pallet to discharge on conveyor.
Lift is pneumatic with a torque tube connecting the two sides for
synchronized lift. Pallet engagement fingers have low force toggle
engagement that lock in place when engaged, yet will not jam if
misalignment occurs.

 FIGURE 16A  FIGURE 16B

Standard Pallet Dispenser Sliding Arm Pallet Dispenser

Sliding Arm Pallet The sliding arm dispenser is suitable for systems that require different
Dispenser for size pallets or systems where queued stacks of pallets are fed into the
Side Pocket of dispenser on conveyor (see Figure 16B).
Wing Pallets
The system has cantilevered arms that slide horizontally to engage and
disengage from the pallet stack. The arms slide on 3" diameter shafts
with bushed bearings. The cantilevered arm carriage is supported by
cam followers and raised or lowered by an electric brake motor.

Product Guide
TopTier 2nd Ed. Rev. A
 Pallet Dispensers
16–2

Capacity is 600 pounds of pallet stacks. Due to limited pallet stack

conditioning capability of the design, loaded pallet stacks from a forklift
or queue conveyor must be uniformly vertical. Loaded pallets exit the
palletizer from all directions except from the pallet load side.

Forklift Style For winged pallets or other style pallets without side pockets, a fork-style
Pallet Dispenser dispenser is appropriate (see Figure 16C). Forks slide horizontally
to engage and disengage the stack. The fork assembly also raises and
lowers. Capacity is a 600 pound pallet stack. Loaded pallets exit the
palletizer in two possible directions.

 FIGURE 16C
Forklift Style Pallet Dispenser

Product Guide
2nd Ed. Rev. A TopTier
 17–1 Layout Options

All palletizers and accessories are modular in design, providing complete

flexibility in the configuration of components and accessories (see
Figure 17A). Layout flexibility in combination with the compact nature of
the base palletizer overcomes nearly any floor space constraint.

INFEED
CONVEYOR

PALLETIZER
FRAME

PALLET STRETCH
DISPENSER WRAPPER

EXIT
CONVEYOR

 FIGURE 17A
Layout Flexibility

Palletizer frames are four-sided. Generally any accessory can be installed

on any side of the frame. The plan view drawings shown in Figures
17B - 17D provide a guide to the flexibility of layout options. Each letter
code references the corresponding component or accessory that may be
installed at that position. All configurations shown can be mirrored for
layout purposes. For additional information, a configuration CAD drawing
is available as well as a configuration utility located on the TopTier web
site.

Product Guide
TopTier 2nd Ed. Rev. A
 Layout Options
17–2

Low Infeed Standard Palletizer n Palletizer Footprint: 80" x 115"

n Infeed positions: B & F
A
n Pallet Dispenser, Empty Pallet Infeed

F B Conveyor, Pallet Jack Access or Load

Exit Conveyor positions: A, C, D & E
n Stretch Wrap or Tie Sheet Dispenser
E C positions: C, D & E

D
FIGURE 17B


Low Infeed Standard Palletizer

High Infeed Standard and Internal n Palletizer Footprint: 80" x 80"

Pre-Build High-Speed Palletizers n Infeed positions: A, B, C & D
n Pallet Dispenser, Empty Pallet Infeed
A Conveyor, Pallet Jack Access or Load
Exit Conveyor positions: A, B, C & D
n Stretch Wrap or Tie Sheet Dispenser
D B positions: A, B, C & D

C
 FIGURE 17C

High Infeed Palletizer

Low and High Infeed Palletizers n Palletizer Footprint: 80" x 144"

With External Layer Pre-build n Infeed Position: A, B & F as shown;
A C, D & E mirrored
n Pallet Dispenser, Empty Pallet Infeed
F B Conveyor, Pallet Jack Access or Load
Exit Conveyor positions: All sides
n Non Concurrent Stretch Wrap: A, B & F
as shown; C, D & E mirrored
E C
n Tie Sheet Dispenser: C, D & E as shown;
A, B & E mirrored
D
FIGURE 17D


External Pre-build Palletizers

Product Guide
2nd Ed. Rev. A TopTier
 17–3 Layout Options

Accessory Footprints
Product Infeed Standard dimensions of the infeed conveyor
Conveyor
are 30" x 84" (see Figure 17E). Alternative
30"
lengths and configurations are available as
required for special applications.
84"

 FIGURE 17E

Product Infeed Conveyor

Pallet Dimensions of the standard pallet dispenser

Dispenser
is 60" x 63" for delivery of pallets in the
narrow (40") orientation (see Figure
63" 17F).

 FIGURE 17F
Pallet Dispenser

Tie Sheet
Dispenser
Dimensions of the standard tie sheet
dispenser is 73" x 73" (see Figure 17G).
73"

 FIGURE 17G
Tie Sheet Dispenser

Stretch Wrap
Tower External
To Palletizer The dimensions of the stretch wrap tower
that extends beyond the footprint of the base
palletizer is 40" x 70" (see Figure 17H).
70"

40"

 FIGURE 17H
Stretch Wrap Tower

Product Guide
TopTier 2nd Ed. Rev. A
 Multi-Line Solutions 18–1

TopTier offers the superior palletizer solution for multiple production lines.
TopTier palletizers replace existing hand palletizing operations and are
installed on new or upgraded multiple production line operations. Legacy
palletizing technology offered solutions that are expensive and susceptible
to a single point of failure. TopTier solutions offer significant improvements
and economic advantage over legacy solutions.

Legacy Multi-Line
Solutions
High-Speed The dominant legacy technology required product from multiple production
Palletizer Fed
from Conveyor- lines to be accumulated on central overhead conveyor and delivered to
Accumulated a single high-speed palletizer. Such systems require extensive space for
Pallet Loads
conveyor that is expensive to purchase and maintain. The high-speed
palletizer becomes a single point of failure that potentially impacts all
production. The potential for failure is increased because the single
palletizer must run at very high speeds to handle all product.

Multi-Line Robots can be used to palletize more than one line concurrently. The
Robotic Palletizers
lines must feed a centralized pickup point and the product must be suitable
for top picking. Robots are characterized by high initial purchase cost as
well as continuing high cost of support. Either plant personnel must be
proficient in the management of complex robotic systems or product
changes must be supported by expensive third party technicians. Robots
are characteristically less tolerant of inconsistently formed product than
are TopTier palletizers.

Multi-Line Gantry systems have many of the same deficiencies as robot systems.
Gantry Palletizer
Systems The capability of gantry systems to pick preconstructed full layers can
be effective, but similar issues arise as those of legacy high-speed
palletizer systems due to the need to accumulate loads on conveyor and
exposure to single point of failure.

Product Guide
2nd Ed. Rev. A TopTier
 18–2 Multi-Line Solutions

TopTier Multi-Line TopTier multi-line solutions have higher throughput potential, alleviate
Solutions single point of failure, require less space and are less expensive to
purchase and maintain than legacy solutions. TopTier solutions consist
of dedicated palletizers for each line. Typical systems employ High-Infeed
palletizers configured in a variety of orientations (see Figure 18A).

TopTier multi-line systems retain all the flexibility and ease of use
characteristic of TopTier palletizers. TopTier systems offer lower purchase
cost, higher rates and better reliability than legacy solutions. Future
product changeovers are significantly easier than for legacy solutions
due to the flexibility of TopTier capabilities.

Systems from TopTier offer lower maintenance cost and are operated
and maintained without special training. TopTier multi-line solutions often
include full and empty load pallet handling and stretch wrapping. Shuttle
carts are available for pallet handling when appropriate. Tie sheet systems,
slip sheet and multiple pallet style handling are available.

 FIGURE 18A
Dual Palletizers with Common External Stretch Wrap

Product Guide
TopTier 2nd Ed. Rev. A
Freight, Installation and Post Sales Support 19–1

Freight Palletizers are shipped in a standard high cube dry van (see Figure
19A). Freight cost is lower than flat bed trailers and the equipment is
protected from the elements until arrival for installation. The integrated
fork pockets built into all palletizer frames allows easy unloading and
equipment placement in the production room.

The customer dock must be suitable for high cube vans with a 110" tall
by 100" wide door. Most customer forklifts can unload the equipment,
but the center distance of the load usually requires dragging the palletizer
from the van. Once removed from the van, one end of the palletizer is
placed on carts and the forklift guides the palletizer into place. A forklift
easily handles all accessories.

 FIGURE 19A
Standard High Cube Dry Van

Installation TopTier palletizers are designed for installation by customer personnel,

with no specialized training required. Palletizers are fully assembled and
pretested prior to shipment. Palletizer accessories are reattached to the
frame onsite. All accessories attach to the frame in a straightforward
manner. Interconnect wiring must be re-terminated in the panel or multi-
strand connectors reattached. All connections are labeled. Machines
designed for palletizing oversized tall loads require on-site placement
of the upper assembly on top the base frame; use of two forklifts or a
single heavy duty forklift is required.

Technicians from TopTier are available to perform the installation onsite

upon request. It is recommended that TopTier technicians provide onsite
startup support for high-speed palletizers and for palletizers equipped
with stretch wrapping.

Product Guide
2nd Ed. Rev. A TopTier
 19–2 Freight, Installation and Post Sales Support

Post Sales Support TopTier palletizers are designed to be operated and supported by in-
house personnel with no specialized training or experience. Onsite
assistance is available upon request for all palletizers at a negotiated
rate. TopTier technicians are in the field at all times, and TopTier strives
to minimize any potential interruption to operations by providing prompt
onsite support. Telephone support is provided at no cost during the first
year of operation.

Schematic drawings, a spare parts list and an operator's manual are

included with delivery of all palletizers. Training of operators or maintenance
personnel is available at no cost during pre-shipment approval at our
facility in Portland OR, or for additional cost at any time at the customer's
site.

Product Guide
TopTier 2nd Ed. Rev. A
 Requirements A1

The following summary of requirements applies to typical applications.

Utilities Power: Three-phase, 30 amp

Compressed Air: 90 PSI, 5 SCFM

Facilities Minimum Palletizer Footprint: 80" x 80"

Minimum Clearance Height: 110"
Dock Door: 110" tall by 100" wide

Product Maximum Layer Weight: 1000 lbs

Maximum Product Length and Width: 38" x 60"
Maximum Load Height: 110"

Pallets Minimum: 24" x 24"

Maximum: 60" x 60"

Installation Forklift: Minimum 4000 pound capacity

Operation & Programming: No PLC proficiency

Maintenance Mechanical: Minimal mechanical skills

Product Guide
2nd Ed. Rev. A TopTier
 A2 Performance Guarantee

EQUIPMENT CAPABILITY

TopTier equipment will palletize and handle materials at the rates outlined in our
quote during the warranty period. New products introduced into production will
also be covered by this performance guarantee with written approval of TopTier,
Inc.

PERFORMANCE GUARANTEE

All TopTier equipment will perform as stated in our quote assuming cases are
square and properly sealed. Performance testing will be performed prior to
shipment with customer-supplied product and customer will confirm acceptable
equipment performance prior to shipment based on supplied video or acceptance
test at our facility.

Should performance problems arise after installation the customer must be aware
quality of palletized loads is a function of the customer case quality. Customer
cases that are poorly sealed top or bottom, bulge beyond the cube of the case,
are sealed as a parallelogram, have loose or improperly sealed over wrap can
affect palletizer performance and or stack quality. Also, broken, damaged or
defectively nailed pallets can affect pallet-handling functionality.

Prior to making a service call, the customer agrees to provide any requested
pictures, video or other descriptive tools to help diagnose any claim of performance
problems. TopTier personnel will promptly provide all possible assistance without
charge to overcome performance problems regardless of the source of the
problem. If performance problems cannot be overcome for any reason after
attempting to correct problems with customer assistance and the equipment does
not perform to these standards, TopTier will make all necessary changes at no
charge to the customer.

However, if it is found that the nonperformance of the TopTier equipment is due

to the operational techniques of the customer's operator(s) or defective product
or pallets, then the customer will be charged in full for the service call.

The customer is responsible for training and familiarizing all operators with proper
TopTier equipment operations and troubleshooting techniques.

Product Guide
TopTier 2nd Ed. Rev. A
 Warranty A1

TopTier, Inc. warrants its manufactured products for a period of one (1)
year from date of installation or 400 days from shipment date, whichever
occurs first to be free from manufacturing defects if installed, maintained,
and used in accordance with factory specifications. TopTier, Inc. will, at
its option, repair or replace any defective parts returned freight prepaid,
subject to factory inspection and right to determine cause of failure.
Damage caused by inadequate supply voltage, normal wear, misuse or
neglect, is not covered by this warranty. Damage in transport is the
responsibility of the carrier and is not covered under our warranty. All
damages upon receipt of equipment should be reported immediately to
the carrier and TopTier, Inc. should be notified.

TopTier, Inc. shall under no circumstances be liable for any consequential

damages, losses or expense arising in connection with the use of, or
inability to use, our product for any purpose whatsoever. Except as stated
herein, TopTier, Inc. makes no other warranty, expressed or implied,
neither does it assume nor authorize anyone else to assume for it, any
other obligation relating to TopTier, Inc. machinery or equipment. This
warranty does not apply to equipment which, in the judgment of TopTier,
Inc., has been subject to misuse, neglect or has been repaired or altered
by unauthorized personnel. Defective parts must be returned to TopTier,
Inc. within thirty days (30) of shipment of a replacement and must be
returned prepaid in their original state. Failure to do so will void the
warranty. Defective parts that have been disassembled, damaged during
removal or otherwise tampered with, will not be covered under warranty,
unless otherwise stated in writing by TopTier, Inc. TopTier, Inc. makes no
warranty as to fitness of equipment for particular purposes. Products
serviced and/or parts replaced during warranty period carry the unexpired
portion of the original warranty only. TopTier, Inc.'s sole obligation under
this warranty will be to provide repairs to components or replacement
parts.

Product Guide
2nd Ed. Rev. A TopTier
 A4 Contact TopTier

TopTier, Inc
5675 SE International Way
Portland, OR 97222-4608

Phone: (503) 353-7388

Fax: (503) 353-7399

sales.team@toptier.com
support@toptier.com
www.toptier.com

Product Guide
TopTier 2nd Ed. Rev. A