High-Level Layer Palletizer
The SunAura SNA-HLP1800 high-level layer palletizer stacks cases, trays, and shrink-wrapped bundles at speeds up to 1800 units per hour with fully automatic layer-by-layer forming. Infeed at 1800 mm floor elevation keeps the operator workspace clear below, making it the workhorse for high-throughput beverage, food, and canning lines where uninterrupted runtime matters.
Product Description
The SunAura SNA-HLP1800 is a floor-level discharge, high-infeed layer palletizer engineered for continuous-production packaging lines. Cases, trays, and shrink-wrapped bundles arrive on an elevated infeed conveyor at 1800 mm, where a sweep-and-push layer-forming head arranges them into a precise layer pattern before lowering onto the pallet. Because the layer is formed above the discharge, the machine body occupies a relatively small footprint while still reaching a stack height of 1800 mm — a configuration that has become standard in large beverage bottling plants and food distribution centers worldwide.
Layer patterns are stored as recipes in the PLC and recalled by product SKU from the touchscreen HMI. A typical case layer for a 1200×1000 mm Eur pallet holds 40–60 retail cases, and the machine completes a full layer in under four seconds. The push bar, side squaring guides, and hopper walls are all pneumatically driven at 0.6–0.8 MPa, with hardened-steel contact surfaces to withstand millions of cycles. Pallet dispense, layer discharge, and pallet exit are fully automatic — one operator can oversee multiple lines from a central control booth.
Every SNA-HLP1800 is load-tested at our Qingdao factory with customer-supplied cases before shipment. Our engineers can also simulate your specific case dimensions and pallet pattern in our design software during quotation, so you see the proposed layer arrangement before you commit. CE-compliant guarding, emergency stops, and interlocked access gates come standard.
Technical Specifications
| Model | SNA-HLP1800 High-Level Layer Palletizer |
|---|---|
| Capacity | Up to 1800 cases / hour |
| Case Weight Range | 5 – 25 kg per case |
| Layer Forming | Automatic, programmable pattern (up to 30 recipes) |
| Pallet Size | 1200 × 1000 mm (Eur) or 1219 × 1016 mm (US GMA), adjustable |
| Max Stack Height | 1800 mm (on pallet, including pallet) |
| Infeed Conveyor Height | 1800 mm (floor-level discharge) |
| Power Supply | 380 V, 3-phase, 50 / 60 Hz (factory-set to order) |
| Pneumatic Supply | 0.6 – 0.8 MPa, dry filtered air |
| Control | PLC + color touchscreen HMI, recipe storage |
| Safety | Interlocked guards, light curtains, emergency stops, CE-compliant |
| Certification | CE Certified, ISO 9001 factory |
Key Features & Benefits
- 1800 cases/hour continuous throughput: The sweep-and-push layer former completes a layer in under four seconds, keeping pace with high-speed bottling, canning, and cartoning lines without bottlenecking.
- Layer-by-layer forming, not row-by-row: Cases are staged in a hopper and pushed across as a complete layer, producing square, stable stacks that wrap cleanly and survive forklift handling.
- Recipe-driven changeover: Store up to 30 pallet patterns in the PLC. Switch SKU from the HMI — no mechanical adjustment needed for standard case sizes.
- Dual pallet-size support: Handles both Eur (1200×1000 mm) and US GMA (1219×1016 mm) pallets by repositioning adjustable side rails — useful for export-focused producers.
- High-infeed keeps floor clear: Cases enter at 1800 mm elevation, leaving the ground level open for pallet exits, fork truck traffic, and maintenance walkways.
- Pneumatic layer squaring: Side guides and end squarers compress the layer before release, eliminating skew and overhang that cause stack failures.
- Automatic pallet dispense and exit: Empty pallet magazine, layer lift, and full-pallet discharge run automatically — minimal operator intervention during production.
- CE-compliant guarding package: Interlocked doors, light curtains at the infeed and discharge, and four-corner emergency stops meet European machinery safety standards.
Application Industries
Beverage Bottling Plants
Carbonated soft drinks, still water, beer, and juice in PET or glass bottles — cases of 6, 12, or 24 bottles stacked layer by layer for warehouse and distribution.
Food Processing
Packaged snacks, cereals, confectionery, and dry foods in retail cases — stable layers keep product undamaged through distribution and retail stocking.
Canned Goods
Vegetables, soups, sauces, and beverages in steel or aluminum cans — cases of 12, 24, or 24+ cans stacked at canning line speeds.
Dairy Processing
Milk cartons, yogurt cups, cheese blocks, and butter in retail cases — handled at chilled-room temperatures with food-grade contact surfaces.
Paper & Tissue Products
Bath tissue, paper towels, and facial tissue in shrink-wrapped bundles — high layer count and consistent pattern for pallet wrapping.
Distribution Centers
Mixed-SKU inbound and outbound palletizing for 3PL operations — recipe-driven changeover between multiple product categories.
Load compatibility: Standard corrugated retail cases, trays with or without shrink film, and bundled products weighing 5–25 kg per unit. Not designed for open bags, loose items, or products over 25 kg — see our Automatic Bag Palletizer for bagged loads.
How High-Level Layer Palletizing Works
Layer palletizing is a mechanical, high-throughput method that builds a complete layer of cases on a staging platform, then lowers that layer onto the pallet as a unit. On the SNA-HLP1800, the cycle runs automatically as cases arrive on the elevated infeed conveyor:
- Cases arrive on the high-level infeed conveyor. Upstream case packers or shrink wrappers discharge cases onto the 1800 mm elevation belt, which feeds them into the layer-forming hopper.
- Singulation and orientation. Cases are separated to a controlled pitch and oriented (long side in or short side in) according to the active recipe. A photoelectric eye confirms each case’s position.
- Layer builds in the hopper. A row pusher places cases side by side until the row is full, then indexes and repeats. Side squaring guides compress each row as it is built, keeping the layer tight.
- Complete layer discharged onto pallet. When the hopper is full for the selected pattern, a cross-belt push transfers the entire layer sideways onto the waiting pallet below. The layer lift descends by one layer thickness.
- Layer repeat until stack height reached. The cycle repeats until the pallet reaches the programmed stack height (up to 1800 mm). A full pallet exits on the discharge conveyor while the next empty pallet takes its place.
Is This the Right Palletizer for You?
The SNA-HLP1800 is the right fit if your operation matches all four of the following. If you fall outside any of them, our team can recommend a different SunAura model:
- Throughput above roughly 800 cases/hour: This machine is rated to 1800 cases/hour and shines on continuous lines. If your line runs under 600 cases/hour, a low-level or compact palletizer will be more cost-effective.
- Cases or trays, not open bags: The layer-forming hopper is designed for rigid corrugated cases, trays, and shrink-wrapped bundles. Open-weave bags, sacks, or poly-bags need a gripper-style bag palletizer.
- Ceiling height above 4.5 meters: The high-infeed configuration requires vertical space — typically 4.5–5.5 m under roof. If your facility has a low ceiling, look at our Low-Level Case Palletizer instead.
- Stable floor-level discharge: The machine discharges at floor level with a built-in lift. If you need to palletize directly from a low, floor-level line without a mezzanine, our low-level model is the better match.
Troubleshooting Guide — Common Issues & Solutions
High-level layer palletizers are designed for multi-shift operation, but line-speed changes, case-size transitions, and wear can introduce layer quality issues. Below are the most common problems our service team diagnoses remotely, their likely causes, and fixes. Always lock out and tag out energy sources before servicing.
| Problem | Possible Causes | Solutions |
|---|---|---|
| Layer skews or cases overhang on the pallet | Side squaring guides out of adjustment; case misalignment from upstream; push bar speed mismatched to case friction. |
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| Stack topples or collapses mid-stacking | Layer pattern has insufficient interlock; cases are damaged or wet; lift descent speed too abrupt. |
|
| Cases jam in the infeed hopper | Case pitch too tight; side guides too narrow; upstream collation off; foreign object in guide rails. |
|
| Layer count not matching recipe | Photoelectric sensor misaligned; rejected case bypass not enabled; PLC recipe not loaded. |
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| Pallet lift does not descend / over-travel alarm | Hoist brake worn; chain tension off; upper or lower limit switch tripped; overload on lift. |
|
| Pneumatic push bar drifts or stalls mid-cycle | Air supply below 0.6 MPa; cylinder seal leaking; solenoid valve stuck; airline filter blocked. |
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If the issue persists after trying these steps, email photos and a short 10-second video of the affected layer to [email protected] — our engineers usually diagnose the root cause within one business day.
Frequently Asked Questions
How many cases per hour can the SNA-HLP1800 handle?
Rated capacity is up to 1800 cases per hour, depending on case dimensions and layer pattern. A typical 300×200 mm case on a 1200×1000 mm pallet runs around 1200–1500 cases/hour in production. Exact throughput is determined by your layer pattern and cycle time — we simulate it during quotation with your actual case dimensions.
Does it work with both Eur and US GMA pallets?
Yes. The adjustable side rails accommodate both 1200×1000 mm Eur pallets and 1219×1016 mm US GMA pallets. Pattern recipes are stored separately for each pallet size. If you run other pallet sizes (e.g., 1100×1100 mm or 1300×1100 mm), let us know during specification — the hopper can be customized.
How tall a stack can it build?
Maximum stack height is 1800 mm including the pallet. On a 150 mm tall pallet, that leaves about 1650 mm of case stack — typically 8–12 layers for standard retail cases. If you need higher stacks (e.g., 2200 mm for warehouse racking), we can extend the lift stroke as an option.
What ceiling height do I need to install it?
Plan for 4.5–5.5 m of clear ceiling height, depending on your stack height and infeed elevation. The infeed conveyor sits at 1800 mm, and the layer-forming hopper and lift extend above that. We provide a general arrangement drawing before you commit to installation.
How long does changeover take between product SKUs?
Pattern changeover is software-driven — select the new recipe on the HMI and the layer pattern updates automatically. For standard case sizes, no mechanical adjustment is needed. If the new case size exceeds the current guide range, a 5–10 minute mechanical guide adjustment is required.
Can it handle shrink-wrapped trays as well as cases?
Yes. The layer former handles corrugated cases, open trays, and shrink-wrapped bundles equally well. The push bar and squaring guides are padded to avoid scuffing printed film. Tray patterns are stored as separate recipes.
Why Buy From SunAura Machinery
48,000㎡ Own Factory
In-house manufacturing in Qingdao, China — no middlemen, no trader markup.
CE Certified
All machines meet European safety standards with full documentation.
ISO 9001:2015
Quality management system certified across the entire production process.
SGS Audited Factory
Third-party audited manufacturing facility with 20+ national patents.
12-Month Warranty
Full warranty covering parts and labor from the date of shipment.
Lifetime Support
Technical guidance via email, WhatsApp, and remote video for the machine’s life.
Spare Parts in 48h
Genuine parts shipped worldwide via DHL/FedEx within 48 hours.
100+ Countries Served
Trusted by packaging lines across food, beverage, pharma, and chemicals.
Get a Factory-Direct Quote in 24 Hours
Tell us your case dimensions, pallet size, and expected line speed — our engineers reply with a model recommendation, FOB price, and lead time within one business day. Every machine is built in our 48,000㎡ Qingdao factory, CE & ISO 9001 certified.
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