CONE PAL, based in Nürnberg, Germany, says it has “started a revolution” in the load carrier market with pallets made of corrugated cardboard. “As many as 15 years ago, my father recognized the potential advantages of pallets made of corrugated cardboard,” recalls Perry Sommer, managing partner of CONE PAL. “They are durable, 100% recyclable, nestable and reusable. What is more, they significantly cut costs along the supply chain for many applications.”

A breakthrough finally came when Sommer worked with a  food company and developed his father’s idea into a solution suitable for the most demanding logistics applications. This collaboration resulted in establishment of the CONE PAL  in 2020. A year later, it installed its first machine for automated production of the innovative pallets. Soon it was operating at capacity, prompting CONE PAL to start up a second machine in late summer 2022 – a system that is the only one of its kind in the world. The adhesive application equipment from Baumer hhs integrated in the machine plays a critical role.

Two-shot gluing process

“We need practical equipment that functions reliably,” says Benjamin Sommer, Perry’s brother and GM of CONE PAL, defining what the company expects of suppliers. “That applies, in particular, to the adhesive application units in the leg erector, a component we also designed in-house. We had to resolve the issue of how to manufacture three legs of different sizes for the pallets in a fully automated process.”

The legs are made from intelligently designed, diecut, corrugated blanks that go through a special folding and gluing step performed by the automated leg erector. The legs are then mounted in the top deck by means of a novel method that CONE PAL has patented. The design, the material and the gluing method together guarantee the stability and durability of both the legs and the entire pallet. The pallets can even carry heavy goods.

After talks with several gluing system suppliers, CONE PAL decided in  spring of 2022 to collaborate with Baumer hhs. “The reliability of Baumer hhs’s equipment, its uncomplicated service and professional technical support are what swayed us,” says Perry Sommer. It became evident that a two-shot gluing process – a combination of hot melt and cold glue application – would best meet CONE PAL’S requirements for erecting the legs.

Depending on their size, the pallets have either six or nine legs. The three leg sizes are necessary because different industries have different requirements for their pallet handling equipment. In terms of load-bearing capacity, there is virtually no difference between the large and small legs. Baumer hhs’s gluing equipment gives CONE PAL a great deal of flexibility in manufacturing the different leg sizes.

Its price/performance ratio is also ideal for this price-sensitive application. CONE PAL selected the HM-500 and DLK go as reliable and low-cost hot melt and cold glue application heads. The Xmelt melter and the cold glue delivery unit are standard products. With this equipment, CONE PAL can accurately apply the precise amount of glue required.

“The combination of hot melt and cold glue was customized to meet our specific needs, meaning it’s a perfect solution for us that promotes the cost-efficiency and sustainability of our products,” notes Benjamin Sommer.

Endless options for customization

CONE PAL can flexibly adapt pallet designs to suit customer needs. For example, the pallets can be printed or provided with a non-slip or additional water-resistant coating. Pallets can be produced in variable sizes and shapes, allowing customers to minimize transport and administrative costs.

Currently, the product range encompasses seven standard sizes, which meet a wide range of requirements. An adhesive application system from Baumer hhs is also in operation at CONE PAL’s second production site in Kevelaer, Germany. “We can basically manufacture pallets worldwide, just-in-time, and locally for customers,” says Perry Sommer, outlining the market potential. “That’s why the scalability of Baumer hhs’s equipment is also so important to us.

“Our pallets can be stacked 40 high. They are also 3.5 cm lower and much lighter than conventional pallets made of wood or plastic. Our customers save a lot of money on transport and reduce their environmental footprint. Fully loaded trucks carrying our pallets instead of wooden ones travel with 700 kg less weight for this reason alone. This explains why the product is named the CONE PAL ‘ant’ – just like the tiny insects, these pallets may be lightweight but they can carry very heavy loads.