A crate feeding system automates the highly repetitive and often strenuous task of de-stacking empty crates and feeding them into a production line. Using mechanical or vacuum-based de-nesting technology, our systems provide a consistent, reliable, and ergonomic supply of crates to your fillers, packers, or robotic cells.

A packaging line running at hundreds of units per minute cannot rely on a human operator to manually feed it empty crates; it creates a major bottleneck and an ergonomic hazard. Our automated crate feeders are the solution. The system typically consists of an infeed conveyor for full stacks, a de-nesting/de-stacking unit that positively separates the bottom crate, and an outfeed conveyor for the single crates. We design robust mechanisms that can handle slightly warped or stuck crates, ensuring high reliability and eliminating a critical point of failure at the start of your packaging process.

    • Technology: Mechanical Gripper De-nester, Vacuum Cup De-nester, Opposing Screw De-nester, Robotic De-stacking
    • Container Types: Plastic crates, totes, trays, baskets, cardboard boxes (cases)
    • Throughput: From 5 to 60+ crates per minute
    • Features: Adjustable for multiple crate sizes, stack infeed magazine, low-level sensor and alarm
    • Integration: Seamless integration with case erectors, case packers, and robotic cells
    • The Crate: Provide samples/drawings, including dimensions and weight.
    • The Stack: How are the crates stacked? Are they nested (inside each other) or stacked (rim on rim)?
    • The Rate: What is the required feed rate in crates per minute?
    • The Line: What is the infeed/outfeed conveyor height and configuration?
Material option A Structure: Stainless Steel 304/316L, Painted Carbon Steel
Material option B Contact Parts: Anodized Aluminum, Polymers (POM, UHMW)
Finish Industrial grade, Sanitary polished (for food environments) Dimensions
Dimensions Custom made design and built by your requirements
For a quote Add to list for quote

More Information

FAQ -

    • Q1: Our plastic crates are often warped or stuck together after washing. How does the system handle this?
    • A1: This is a very common problem we design for. Our mechanical de-nesters use positive gripping or opposing screw mechanisms that physically force the crates apart. Vacuum systems can be programmed to apply a short, powerful puff of air to break the seal between nested crates, ensuring only the bottom one is dispensed.
    • Q2: Can a single system handle multiple crate sizes?
    • A2: Yes. We specialize in flexible systems. The de-nester magazine and guides are typically designed with quick-release handles and digital position indicators, allowing an operator to perform a changeover for a different crate footprint or height in a matter of minutes, without tools.
    • Q3: What is the main benefit of automating crate feeding beyond just saving labor?
    • A3: Ergonomics and consistent line performance. Manually de-stacking crates, especially from low pallets, is a leading cause of back and shoulder injuries. Automating it eliminates this major ergonomic risk. Additionally, an automated feeder provides a smooth, consistent, and predictable supply of crates, allowing your downstream equipment (packers, fillers) to run at its optimal, steady speed without starving.
    • Q4: When would you recommend a robotic de-stacking solution instead of a mechanical de-nester?
    • A4: A robotic solution offers superior flexibility. It's the ideal choice when you need to handle a very wide variety of crate sizes, when you need to de-stack from multiple pallet positions, or when the robot needs to perform additional tasks, such as placing the crate in a specific orientation or handling slip sheets between layers.
    • Q5: How is a new stack of crates supplied to the machine?
    • A5: The system is typically fronted by an infeed conveyor (belt or roller). An operator can place one or more full stacks onto this conveyor. The system automatically senses the presence of the stack, conveys it into the de-nester's magazine, and provides an alarm (e.g., a stack light) to the operator when the infeed conveyor is empty and needs to be reloaded.