Why REEMAN Developed Its Own Ramp-Free Automated Pallet Wrapping Workstation

Why REEMAN Developed Its Own Ramp-Free Automated Pallet Wrapping Workstation

Autonomous forklifts can move pallets without drivers. Automatic stretch wrapping machines can package palletized goods without manual film application. But making both systems work together reliably requires more than simply connecting two machines.

Forklift access, pallet transfer height, equipment communication, and workstation layout all affect the performance of automated pallet packaging.

To address these challenges, REEMAN has independently developed its own automatic stretch wrapping machine and upgraded the workstation specifically for autonomous forklift operations.

The new design eliminates the conventional loading ramp, enables direct pallet placement and retrieval, and coordinates the entire process through wireless equipment communication.

1. Why Did REEMAN Develop Its Own Automatic Stretch Wrapping Machine?

REEMAN has previously integrated autonomous forklifts with existing industrial wrapping equipment through wireless communication modules.

These solutions demonstrated how independent machines could exchange commands and operating status to coordinate pallet transportation and packaging.

However, wireless communication alone cannot solve every integration challenge.

Even when two machines communicate successfully, the forklift still needs to approach the wrapping platform, place the pallet accurately, withdraw from the equipment area, and return for collection after packaging.

Conventional wrapping stations may require additional access structures, including loading ramps. These structures occupy floor space and introduce extra movement requirements.

REEMAN's development objective was therefore not simply to automate the wrapping command, but to redesign the workstation around the actual movements of an autonomous forklift.

By developing the wrapping equipment in-house, REEMAN can consider mechanical access, pallet handling, control signals, and workstation layout together during system design.

This approach represents a shift from connecting separate machines to developing an integrated automated packaging workstation.

2. The Core Engineering Upgrade: Ramp-Free Pallet Handling

The most important mechanical improvement is the redesigned wrapping station base.

In the previous ramp-based configuration, the forklift needed an access ramp to approach the wrapping platform.

REEMAN's new workstation eliminates this requirement by providing a designated fork-access area beneath the wrapping platform.

The autonomous forklift can approach the workstation, insert its forks into the designated access area, place the pallet in position, and withdraw without driving up a loading ramp.

What Are the Advantages of This Design?

Actual floor-space savings and efficiency improvements depend on the workstation configuration and factory layout.

3. Real Demonstration: REEMAN's Self-Developed Workstation in Operation

REEMAN has demonstrated the upgraded workstation using its Rhinoceros autonomous forklift, also known as the Rhino Stacker.

The demonstration shows how the forklift automatically collects a pallet, transports it to the wrapping machine, completes the packaging handover, retrieves the finished load, and delivers it to the designated destination.

The complete operating cycle takes approximately 5 minutes. This includes transportation, wrapping, retrieval, and final delivery.

The video presents selected stages of the demonstration. The approximately 5-minute operating cycle refers to the complete process, not the edited video duration.

Watch on YouTube: https://youtu.be/hDxZet7SFX4

4. How Did REEMAN Integrate Wireless Communication into the Workstation?

Mechanical compatibility allows the forklift to handle pallets at the wrapping station. Reliable automatic operation also requires the machines to coordinate their tasks.

REEMAN's wireless integration approach enables the autonomous forklift and wrapping machine to exchange task commands and operating-status information.

Depending on the controller configuration, external wireless communication modules can connect through industrial interfaces such as:

• I/O - Digital control and status signals
• RS485 - Serial industrial communication
• Ethernet - Network-based industrial communication
• CAN - Controller communication

The wireless link between equipment-side modules can use technologies such as LoRa or Wi-Fi, depending on the application and system configuration.

How Does the Automatic Equipment Handshake Work?

The key feature is two-way task communication. The forklift and wrapping machine exchange the information needed to coordinate successive operations, rather than relying on an operator to manually start each step.

Safety interlocks, personnel protection, and emergency-stop functions must be separately designed and validated. Ordinary wireless task communication does not replace machine safety systems.

5. Why Did REEMAN Include Adjustable Wrapping Layers?

Automated packaging must accommodate different pallet loads and product characteristics.

Some goods require additional film coverage for load stability, while other palletized products may be adequately secured using a different wrapping configuration.

REEMAN's automatic stretch wrapping machine supports adjustable wrapping layer settings, allowing the wrapping program to be configured according to actual packaging requirements.

This provides flexibility for factories handling different palletized products and helps operators select appropriate film usage and load-protection settings.

The selected wrapping program should be validated according to the load's stability, packaging requirements, and transportation conditions.

6. Why Is the Workstation Designed for Rhino and Mini Autonomous Forklifts?

The upgraded workstation currently supports two REEMAN autonomous forklift models, providing options for different pallet-handling applications.

Rhinoceros Autonomous Forklift Trucks 3.0

The REEMAN Rhinoceros Autonomous Forklift Trucks 3.0 is the model featured in the workstation demonstration.

With a rated load capacity of 1,500 kg and a lifting height of up to 2.5 m, it is designed for automated pallet handling in manufacturing and warehouse environments.

Its Laser SLAM navigation and autonomous material-handling capabilities support pallet pickup, workstation handover, and finished-goods transportation.

Mini Autonomous Forklift

The Mini Autonomous Forklift offers a more compact configuration for suitable pallet-handling environments.

With a rated load capacity of 1,000 kg and lifting height of up to 1 m, it provides another option for integrating autonomous transportation with REEMAN's automatic wrapping workstation.

Final compatibility depends on pallet dimensions, fork openings, transfer height, load weight, and available operating clearances.

7. What Does In-House Development Change for Factory Automation?

For manufacturers evaluating automated pallet packaging, the challenge is often not the performance of an individual machine.

It is the connection between material transportation, packaging equipment, and the next production or warehouse operation.

By developing both the wrapping equipment and its integration approach around autonomous forklift operations, REEMAN can address several engineering requirements within one workstation design.

This approach reduces the separation between automated transportation and packaging operations.

Instead of treating the wrapping station as an independent process requiring manual coordination, it becomes part of a connected material-handling workflow.

During normal operation, the workstation can reduce repeated manual forklift driving, wrapping initiation, and finished-pallet handling.

Operators remain responsible for maintenance, film replenishment, fault recovery, and necessary safety supervision.

8. What Should Manufacturers Evaluate Before Deployment?

A successful automated wrapping project requires the workstation to match actual factory conditions.

Before installation, manufacturers should evaluate several engineering factors:

• Pallet Compatibility: Dimensions, fork openings, load weight, and load center.
• Available Space: Forklift approach paths, turning clearance, transfer height, and safe withdrawal areas.
• Wrapping Requirements: Film layer settings, pallet stability, and packaging specifications.
• Communication Interfaces: Available controller connections, task signals, completion feedback, and fault handling.
• Safety Management: Machine guarding, interlocking, personnel protection, emergency stops, and maintenance access.

These requirements determine whether the equipment can be integrated reliably into the existing production and logistics environment.

Frequently Asked Questions

Conclusion: Developing the Workstation, Not Just Connecting the Machines

REEMAN's upgraded pallet wrapping workstation demonstrates why in-house equipment development matters for factory automation.

The main advancement is not simply enabling an autonomous forklift to communicate with a wrapping machine. It is designing the mechanical structure, pallet transfer process, and equipment coordination around one automated workflow.

By combining its self-developed stretch wrapping equipment, ramp-free pallet access, wireless coordination, and autonomous forklift technology, REEMAN provides a more integrated approach to automated end-of-line packaging.

The Rhinoceros demonstration shows how the complete pallet pickup, wrapping, and finished-goods delivery process can operate in approximately five minutes.

From standalone automation to an integrated smart workstation, REEMAN continues developing practical solutions for real factory material-handling requirements.