RPL-1000
REPALLETIZER
RPL-1000
High-speed repalletizer | automated empty can stacking | can decorator and beverage packaging line
The CODI RPL-1000 is a can re-palletizer that stacks loose empty cans onto pallets at up to 1,000 CPM with automatic slip sheet placement between every layer. An encoder-driven hoist lifts the pallet to build height, mass-table primes each layer, and the sweep runs without operator input. Top-rack confirmation runs before final lowering. A large touchscreen HMI covers auto and manual modes, can-size configuration, and live hoist status. Purpose-built for digital can printing and decorating, co-packing, and high-volume beverage operations.
The CODI RPL-1000 is a can re-palletizer that stacks loose empty cans onto pallets at up to 1,000 CPM with automatic slip sheet placement between every layer. An encoder-driven hoist lifts the pallet to build height, mass-table primes each layer, and the sweep runs without operator input. Top-rack confirmation runs before final lowering. A large touchscreen HMI covers auto and manual modes, can-size configuration, and live hoist status. Purpose-built for digital can printing and decorating, co-packing, and high-volume beverage operations.
PRODUCT FEATURES
Encoder-Driven Layer Positioning
The electric hoist uses encoder feedback to hit exact layer height every cycle. Clutch-driven leveling keeps each layer square before the sweep runs.
Automatic Slip-Sheet Placement
Slip sheets are placed between every layer without operator handling. No manual intervention needed between layers.
Full Palletizing Cycle Automation
From layer sweep to top-rack confirmation to full pallet lowering and eject, each step is sequenced and controlled. Auto and manual modes give operators flexibility for setup and diagnostics.
Tool-Free Access to Wear Points
Suction cups, UHMW guides, bearings, chains, belts, and motors are all accessible without tools. Maintenance doesn't require a wrench or a long downtime window.
PRODUCT INFORMATION
Up to 1000 CPM
Auto Slip Sheets
Perfect for Digital Printers
Performance & Capacity
Operating Speed: Up to 1,000 CPM (60,000 CPH) under ideal line conditions
Container Compatibility: Aluminum beverage cans (Standard, Sleek, Slim, King Cans up to 24 oz / 750 mL) and aluminum bottles
Pre-Loaded Can Heights: 14 pre-programmed standard container recipes plus 4 custom user-defined memory slots
Pallet Sizes: Standard bulk beverage can pallets (44" × 56") with programmable layer counts (up to 21+ tiers / 110" full pallet height)
Elevation Hoist System: Heavy-duty Nord 2HP brake motor with dual 1-3/8" output shafts, Hersey Protek-Sure torque-limiting clutches, and dual IFM 31-bit multi-turn absolute IO-Link encoders
Physical Dimensions & Clearance
Standard Overall Footprint (L × W × H): 298.3" × 90.2" × 188.2" (7,576 × 2,290 × 4,780 mm)
Mass Infeed Conveyor Dimensions: 180" L × 66" W frame (52.75" modular flush-grid belt width)
Tin Line Heights:Mass Infeed Conveyor Tin Line: 151.1" (3,838 mm)
Pallet Discharge Tin Line: 11.5" (292 mm)
Ceiling Height Requirement: Minimum 200" (16' 8" / 5,080 mm) overhead clearance
Machine Weight: Approx. 4,800 lbs (2,177 kg)
Utility Requirements
Electrical Supply:380–500 VAC, 3-Phase, 50/60 Hz, 15 Amps Full Load (Standard)
208–240 VAC, 3-Phase, 50/60 Hz (available upon configuration)
Compressed Air:8 SCFM intermittent @ 100–110 PSI constant (clean, dry air meeting ISO 8573-1:2010 Class 2)
Dedicated 1/2" ID supply line (3/4" ID recommended) to onboard Festo air prep station with soft-start valve, digital IO-Link pressure monitoring, and emergency safety air dump
Pallet Handling & Logistics
Powered Pallet Infeed Conveyor: Heavy-duty chain conveyor sections to stage empty wood pallets automatically into the hoist.
Automated Full Pallet Discharge: Powered outfeed roller or chain conveyor sections that transfer completed pallets directly to downstream stretch wrappers.
Corner Turn Pallet Conveyance: 90-degree corner pallet transfer modules engineered to accommodate compact or L-shaped floor plans.
Automatic Empty Pallet Unstacker: Automated pallet de-stacking magazine that feeds single wooden pallets into the machine on demand.
Quality Control & Layer Management
"Bad Row" Vacuum Pickup System: Integrated row-separation fingers and vacuum suction cups that isolate, pick up, or set down partial or defective rows before sweeping.
Mass Table Can Bump Wedges: Low-friction UHMW pack-forming wedges that maintain tight, nested can patterns across the accumulation table.
Conveyor Primed Sensing Array: Multi-point retro-reflective optical sensors ensuring a complete, gap-free layer is formed prior to sweep initiation.
Top Picture Frame Placement Support: Automated staging and placement assists for protective wooden top picture frames.
Safety & Operator Access
Perimeter Safety Enclosure: Industrial steel wire mesh safety fence guarding the pallet conveyor and hoist travel zones.
Optical Safety Light Curtains with Muting: Integrated entry and exit light curtains that permit pallets to enter and exit automatically while halting machine motion if personnel cross the safety perimeter.
Upper Catwalk & Inspection Mezzanine: Elevated inspection platform with safety handrails and ladder for overhead can pack monitoring.
Finish & Maintenance
Custom Powder Coat Finish: Frame and structural guards finished in custom industrial powder coat colors to match your brand, facility, or existing line aesthetic.
Curated Spare Parts Packages: Tiered maintenance kits (Festo linear actuator belts, pneumatic cylinders, vacuum suction cups, optical sensors, and drive chain guides) to maximize production uptime.
High-Speed Servo Mass Layer Stacking
Built specifically to handle high-speed container output downstream from digital can printers, label applicators, or can manufacturing lines.
Employs high-precision Festo ELGA belt-driven linear actuators paired with a 3,000 RPM Festo brushless servo motor and CMMT-AS drive.
Gently pushes entire nested tiers of empty cans across the deadplate onto the pallet in one continuous, vibration-free stroke.
Dual-Encoder Self-Leveling Chain Hoist
Driven by a 2HP Nord gearmotor with dual output shafts and heavy-duty ANSI roller lift chains.
Dual Hersey Protek-Sure torque-limiting clutches isolate mechanical overloads and allow independent hoist-level adjustment using the included CODI calibration wrench.
Dual IFM 31-bit multi-turn absolute encoders continuously monitor left- and right-side hoist elevation, guaranteeing sub-millimeter deck leveling across millions of cycles.
Active 4-Way Layer Squaring & Containment
To ensure pallets remain straight, stable, and secure during transit and storage, the RPL-1000 actively squares every tier:Upper Layer Squaring: High-stroke pneumatic side jaws clamp and align the incoming can tier prior to transfer.
Lower Layer Squaring: 4-way pneumatic jaws (Infeed, Left, Right, and End) square the palletized tier below to lock cans into a rigid, uniform column.
Eliminates staggered rows, leaning can stacks, and loose layers.
Integrated Automated Slip Sheet Placement
Features an overhead pneumatic slip sheet arm equipped with multi-fold Festo bellows suction cups and pneumatic vacuum generators.
Automatically lifts a slip sheet from the staging rack and places it flat across the freshly swept layer of cans as the carriage returns, completely removing manual slip sheet handling from the packaging line.
Intelligent Touchscreen Control & Recipe Memory
Centralized Phoenix Contact 15.6" widescreen color touchscreen HMI (1200 × 800) powered by Schneider Electric PLC automation.
Recipe memory stores 14 standard container formats (from 5.5 oz slim to 24 oz standard) plus 4 fully customizable user slots—automatically recalculating layer heights, transfer offsets, and pack widths at the touch of a button.
On-screen diagnostics display real-time sensor I/O status, cycle speeds, lifetime layer/pallet counts, and configurable 6-tone alarm buzzer options.
ACCESSORIES
RESOURCES
FAQ
What does a repalletizer do?
A repalletizer runs the depalletizing sequence in reverse. Instead of unloading cans from a pallet into a filling line, it takes loose or processed containers and stacks them back onto pallets with slip sheets between layers, ready for storage or shipment.
Who uses the RPL-1000?
Can decorators, mobile canning operators, beverage producers running off-site warehousing, and facilities that need to buffer empty or filled cans between production steps. Any operation that receives bulk cans, modifies them, and needs to palletize them again.
How does the RPL-1000 keep layers stable during stacking?
An automated sweep mechanism forms each layer on a staging table before transferring it onto the pallet, while an integrated slip-sheet dispenser places dividers between tiers. That automated layer formation maintains tight tolerances so stacked pallets stay stable in transit.
Can the RPL-1000 pair with a depalletizer?
Yes. Pairing an RPL-1000 with a DPL-1000 depalletizer creates a continuous decoration or repack loop: cans leave the depalletizer, pass through your labeling, sleeving, or printing equipment, and immediately re-stack on the RPL-1000.
