Left to right: Ron Wouters (co-owner, Dücker Prefeeder); Peter Dücker, and Erik Meulendijks (co-owner, Dücker Prefeeder).
Fris Karton BV in Bladel, the Netherlands is a producer and supplier of corrugated packaging. For over 35 years, they have been producing corrugated packaging for a wide range of products for customers in the Netherlands and Belgium.
The company is well invested, and following a significant factory expansion and the addition of a new high speed EMBA QS Ultima casemaker, the company needed to add a highly efficient palletizer to help ensure maximum output could be reached comfortably. They turned to Dücker Prefeeder.
Innovation at the fore
Founded in 2015, Dücker Prefeeder BV has leveraged experience dating back to 1990 to develop a new-generation pre-feeder, which it successfully commissioned in 2016. Since then, the company have delivered nearly 150 pre-feeders worldwide, in Western Europe, USA, Latin America, Australia, and the Middle East.
The PAF1600
In 2023, Dücker Prefeeder took the next step by introducing a fully automatic Palletizer, initially designed for use behind flexo folder gluers such as EMBA QS Ultima series and Bobst 618/718/924/1228 and 1232. Built upon the company’s well-known DP platform, this new palletizer upholds the highest standards in modularity, reliability, ergonomics, and value for money.
When developing this system, the specialist machine builder prioritised three key factors:
- Compact footprint: fitting seamlessly into tight factory spaces behind ever kind of longer case-maker;
- Energy efficiency: designed with sustainability in mind;
- Future-proof technology: high-speed, full-size palletizing capabilities.
A game-changer
“The PAF1600 pushes the performance of your converting machine to the limit, maximizing space utilisation and manpower efficiency. With converting lines growing ever longer and factory space at a premium, automation is no longer a luxury; it is a necessity,” explains Erik Meulendijks, Owner & Sales Manager, Dücker Prefeeder BV.
“Thanks to the new system, Fris are able to alleviate issues with labour costs and shortages; the whole project highlighted the need for automated solutions. Investing in a fully automatic palletizer ensures higher productivity and reduced operational costs.”
Next-Level Productivity
Partnering with cellumation GmbH, Dücker Prefeeder have redefined layer-composing technology, elevating productivity to unprecedented levels. Since its introduction in October 2024, the system has delivered tangible results.
As the first customer, Fris Karton has experienced a significant increase in output, with faster and more precise palletizing, reducing both workload and error rates.
Rob Smets, Owner, Fris Karton, explains, “We chose Dücker Prefeeder’s solution because of its special combination of innovation and proven technology. Despite its simplicity, positioning and formatting work like magic before our eyes. It was an exciting and insightful project from start to finish, thanks to Dücker Prefeeder’s expertise.”
Smart Layer-Forming
The patented celluveyor technology ensures precise pallet layer formation, enabling seamless format changes without downtime.
Operators can define any stacking pattern via our future-proof PAF-HMI software, ensuring maximum flexibility. Robotic ‘eyes’ monitor the shape and positioning of every single banded bundle, and then moves it and refines its position, prior to forming of the bundles in the palletizer unit.
Safety First
At Dücker Prefeeder, operator safety is a top priority. That’s why they have designed the systems with non-hazardous, intelligent modules, minimising risks while maximising efficiency.
“Built-in safety features eliminate potential hazards,” says Meulendijks. “User-friendly design ensures effortless and risk-free operation. Also, automated processes reduce the need for manual intervention, enhancing workplace safety. With our state-of-the-art safety measures, your team can work with confidence and peace of mind, while maintaining maximum productivity.”
A Seamless Combination
Meulendijks concludes, “Our pre-feeders and palletisers share the majority of components, making them the ideal one-stop solution for both the front and back of any casemaker. We successfully designed and commissioned the PAF1600 Palletizer in just one year — a challenge we completed with the invaluable support of cellumation GmbH. The celluveyor technology is the key to this game-changing system.”
