LoadMatic^® FAQ

• The 1^st LoadMatic has been supplied more than 10 years ago. Since then, we have been supplying more and more Systems to various customers all around the world from different customer segments.
• Our experts will advise you with reference sites.
• We have installations all around the globe and what’s better than getting feedback directly from the people who work with our Solutions.

• The Equipment is design for a lifetime of +25 years. Regular maintenance and continuous upgrades allow our customers to extend this lifetime.

• The good thing is that LoadMatic is designed to load non-modified trailers and Containers and it gives you the freedom and flexibility to choose your forwarder.

• The pure loading (aligning to truck, plate in, blocked, plate out and re-aligning with home position) takes 5-7 mins. When it comes to capacity it’s necessary to also consider the time for preparing the load and the docking (in and out) of the truck. Preparing of the load is related to availability of goods. As faster the goods are available as faster preparation. As an indication 15-20 mins for a full loading cycle is a good value and would allow to load up to 3-4 loadings per hour.
• Our experts will support you finding the right capacity for your solution.

• Our solutions are designed to align with the Trailers. Hydraulics allow us to move the machines horizontally and vertically. This can be done manually or optional Automatically.

• Optional Automatic camera- and scanner systems can be added to provide inspection details. Our experts will advise you on this.

• LoadMatic, other than other Systems, is capable to handle various load patterns and various pallet types. The grade of Utilization of your Trailer/Container is highly depending on the pallet type and the load pattern you are intending to use. Our experts will advise you.

• Availability is 98%. When taking care and treating our solutions in the right manner it can be increased.

• System can be designed to ensure contingency in case LoadMatic is down for some reason. Our experts will help you to find the right strategy.

• LoadMatic will reduce the traffic at your loading dock dramatically and increases your operational safety. It will load the Trailer/Container in one shot which will be a faster and highly efficient loading. It does not require a step dock and dock leveller which allow you to build your Warehouse / Shipping area on ground level. No additional costs for raising the floor height.

• Yes. Our solutions are designed in accordance with EC/2006/42 regulation for machinery safety as well as applicable local safety standards.

• LoadMatic is designed to load non-modified cargos like Containers and Trailers. Modified Systems are used for transferring goods from A to B as you can always use the same trucks.

• LoadMatic can be integrated into new- and existing buildings. Our Experts will support you with the requirements.

• Drop offs require a correct sequence of Pallets. Sequencing can be done by using existing sequencing conveyor / marshalling lane systems, monorail / conveyor loops, AGV workorder sequence, with forced ASRS outfeed sequence. If you don’t have the ability to provide them correctly, we can offer you our Sequencer Technology.

• In standard situations, the HMI is located in the field near the loading systems for manual operation with clear visual overview
• LoadMatic has been invented in Finland where ambient temperature can be easily below -10°C. Further our LoadPlate has been designed for outdoor operation. We have also provided ASRS Systems to cold storages in the past. All those experiences help us when it comes to cold storage requirements. For cold storage applications we will add heating system to ensure the viscosity of the hydraulic oil and to avoid condensation on sensors and HMI.

• 85 docks are a result of required outbound capacity based on manual loading by FLT. Cycle time for manually loading of a full load is approx. 60min. As LoadMatic is capable to do 3 loads per hour you can have the same number of loadings with only 28 docks. Using LoadMatic will also beneficial for your operational costs as you need to facilitate less FLTs, less docks and less employees.

• The LoadMatic system allows loading of palletless products if certain technical requirements are met.
• Pallet removal (depalletizing) can be included as part of the LoadMatic line

• LoadMatic system is the most flexible ATLS solution on the market and can handle a wide range of pallet types with various dimensions
• Can be used with i.e. wooden, plastic, steel, and with some cardboard pallet types
• Product with overhang over the pallet can also be loaded, if it fits through the trailer door opening

• The loading principle of LoadMatic is based on so called “plate technology”, where full load is resting on top of the loading plate
• The weight of the product is equally distributed around the floor surface of the container/trailer
• Loading plate is flexible, and can forgive the bumps and dents in the floor

• Yes, Actiw’s broad experience in automated warehousing and intralogistics allows to integrate into almost any ERP / WMS / WCS

• Absolutely, we have delivered multiple LoadMatic lines for loading palletless products on slip-sheets, such as for example carton boxes.

• Most definitely yes, such connection would mean the full automation which goes well with our vision.
• When connecting to ASRS, we create the interface with existing conveyors.
• In case of AGV infeed we include 2 drop-off points, in order to maximize the capacity and prevent the queuing of AGVs

• Yes, the sensor raw data can be collected from LoadMatic’s PLC using standard protocols.
• In case of higher-level integration, we offer our software, which filters and processes the data and presents it in a suitable way for tracking the custom KPIs

• Barcode / QR / RFID scanners can be included into the LoadMatic line in order to collect the individual product unit IDs, which will be used in the shipping manifest.
• Unit tracking helps to prevent the wrong shipments and other operational mistakes. The product unit ID can be compared with the pre-received shipping manifest (received from i.ex. WMS / ERP), and after loading is automatically removed from the warehouse stock.

• The load-forming process (getting the product on top of LoadMatic system) usually takes less than 15min, which means that it can be initiated after the truck has been confirmed on site and started the check-in process at the main gate.
• We can offer our modular load buffering solutions, which can store anywhere between 1 and 30 full truck loads, and quickly feed the correct units into LoadMatic system when required. Such buffer system in combination with LoadMatic can output up to 100 pallets per hour, basically ensuring no more than 15 minutes

• We are independent supplier and systems integration company and regularly work with a wide range of suppliers both locally and internationally to be able to provided ‘best-in-class’ solutions for our customers. We will work with customer selected or preferred sub-suppiers to effect the a solution that best suits the customer’s needs both short and long term.

• Product overhang is quite acceptable. In such situations the product faces of the pallet loads will be in contact, not the pallets, at certain times during load forming and loading. The low friction, low profile roller bed ensures gentle handling and product-to-product contact forces that are typically less than encountered in forklift loading or gravity lane use.
• If there is variable product overhang that at times causes the total width of the load to exceed the door width of the container or trailer then the profile control system will halt the loading process so that check and rectification measures can be taken as required, or the pallets in the row are moved to the ‘reject’ outfeed.
• When loading trucks or containers with a one-shot loading system, the total load is transferred inside the truck in one motion This means that the door opening dictates the total width of the load. Sometimes the trailer door opening is narrower than the internal width of the trailer, due door hinges or roll door guides:  For example if 3 EUR pallets are loaded with short side leading into the trailer, the width of the row is 2,4m, while trailer door opening is 2,46-2,48m. This leaves 3cm free tolerance each side for the loading, and thus does not allow too much overhang on the pallets.

• All the functions of LoadMatic are fully automated. The presence of the operator is required to initiate and monitor the loading process, which takes ~7 minutes.
• The load forming stage (getting goods on top of the LoadMatic) is fully automated and doesn’t need operator intervention.
• After load forming is completed, the system signals to the operator that the loading cycle can be started.

• High volume automated loading systems require the necessary infeed flow of pallets. This can be well over 100 pallets per hour. The LoadMatic System if placed on an existing dock and utilizing the existing dock door will extend into the warehouse a similar distance to the vehicle being loaded.
• Depending on the existing dock layout, this may create some issues with traditional dock material flows, which tend to be across all the existing docks
• Generally these issues can be greatly reduced by the positioning of the system, so that the cross traffic will not be significantly impacted.
• It is important to also realize that the implementation of high-volume one-shot loading systems will significantly free up 3-4 manual docks and their adjacent staging areas so that overall space is reduced for the same outbound volume.
• In greenfield cases, we can work with you with the layout design stage, applying the experience gained over hundreds of systems and 25 years in supplying  non-modified truck loading projects. This way the system and investment size can also be streamlined to have most cost-effective solution tailored to your current and future needs.

• Before pallets are accepted to LoadMatic, the pallet row goes through a profile check station. This checks the outer dimensions of the pallet row (including the possible overhang), to ensure that the pallets can fit through the door opening without issues.
• Before the loading sequence commences, LoadMatic is automatically aligned with the trailer with scanning the centreline of the trailer. This is achieved to a very high accuracy. This allows us to achieve tolerances on loading as small as 1cm between each side of the opening to the trailer or conatinerallowing the maximum usage of the door opening  and accurate loading without impacting the sidewalls or incurring product damage.

• In standard situations, the HMI is located in the field near the loading systems for manual operation with clear visual overview
• If detailed monitoring is required, due to the size of the dispatch operation or location of the dock then full system controls and monitoring we can provide LoadManager software to complement the loading system. Then the monitoring screens are easier to be located in central control room. This software can be also viewed with tablet on field, as it can be viewed with internet browsers.

• Profile check is the last point of ensuring the pallet row is capable in fitting through the trailer / container door
• It checks that the profile of the row is not exceeding the set limits.
• Should the profile check detect that the row is too wide to fit through the door, an alarm is raised and the operator can inspect and check if the loading can continue or if the pallet row needs to be sent to the reject conveyor for rework.

• If the dimensions of the pallet row are outside the tolerances  accepted by the profile control system at the grouping station, the pallets in the row will be diverted to the reject conveyor
• After rejecting, the operator can pick up the pallets with a forklift, do any necessary rework (for example fix excessive leaning of the pallet stack) and then re-enter the goods back to the LoadMatic using the same conveyor

• Yes, these functions are availableand have been supplied on a numer of systems.
• Weight Data: Weight of each pallet can be either received from ASRS / ERP system, or from barcode if the information exists, or by integrating a pallet weighing system on the infeed conveyors. Total load weight data can also be registered by load cells on the LoadMatic system.

• The equipment is simple to operate and usually handled by current employees following some basic training and understanding of the system. Typically our customers re-train their forklift drivers to operate our ATLS systems. In some operations the truck drivers themselves are operating the system.

• Floor load of the LoadMatic is spread over two or three leg pairs. Under each pair, the floor load have to carry LoadMatic with full load. In case the existing floor strength is slightly less than the required, we are able to modify the feet of LoadMatic to have larger surface area to distribute the pressure.
• Door opening is recommended to be minimum 3x3m
• Free space above and around door is also required for maintenance access, and to ensure that LoadMatic does not hit building columns when doing the alignment.
• Around the loading system sufficient space is also required

• In normal operations, power is consumed only when pallets are being moved. When the system is in standby mode, only minimal power is consumed.
• Power consumption of the system depends on the product flow in terms of how many pallets per hour the line is handling, and how many truckloads are loaded per hour.

• If the LoadMatic is designed to load only sea containers, we can have supporting pins and clamping device in the front of LoadMatic. Supporting pins are holding the container on the correct level during the loading, thus preventing sinking of the trailer during loading. Clamping device creates then interlock with the container, preventing it from moving during the loading process, thus acting as “wheel restraint” of a sorts.
• With trailer loading, LoadMatic has automatic height adjustment feature, which tracks the height movement of the trailer during the loading sequence and adjusts LoadMatic height accordingly.

There are two ways this is normally handled:

• With our proprietary Actiw LoadManager software, we can provide single connection point to Your system which acts as the filtering / reporting tool
  • Actiw LoadManager has web UI, which can be used with standard PC’s in the same network. The KPI’s and reports can be tailored according to your needs and how you want to track your operations and performance of the equipment.
  • Actiw LoadManager can also act as integration process tool between LoadMatic system and your other systems like ERP, WMS etc…

• • Alternative option is to have direct connection with DCS/IoT platform providing the raw data from the equipment.
• In both versions machine data is mined directly from the PLC logic of the equipment.

• Yes, multiple different patterns are possible to either maximize the fill rate or to achieve optimal weight distribution on the truck axle weights.

• LoadMatic is extremely flexible with the loading patterns and different pallet types which need to be loaded, and also palletless.
• Even different pallet sizes can be mixed in the same load with certain cases, this requires that the pallet sequence is correct when entering ATLS system. Such sequencing can be done either in automatic warehouse, or alternatively we are happy to investigate different Actiw buffer sequencer options with you.

• 30 000kg / 66 000lbs as standard
• Special designs are also possible for higher payloads

• Thinking for the next generation already? You’ll be probably retired when the equipment would need to be decommissioned
• The lifespan of the equipment is designed to be 25 years, and with proper maintenance and refurbishment it can be extended
• If You’d really like to decommission the equipment, you should contact us again and we can see whether we are able to find new home for the equipment
• If the decommissioning is the only alternative for the equipment, we are more than happy to advice you on the materials used and how to recycle them, by providing material safety data sheets etc.

• Standard documentation for the equipment includes the maintenance and cleaning schedules and instructions as standard to ensure that the equipment lasts over the designed lifespan of 25 years.

• For the equipment itself, no other special maintenance is foreseen apart from changing the plastic plate on the bottom.
• Normal maintenance checks are done on monthly basis, were chain tensions and sensor positions etc.
• Get in touch and we are happy to show your maintenance team the maintenance documentation of the equipment.

• Pallet quality is the most common issue. It can be either from board deflection/out-of-spec pallet dimensions, or overhang issues, where profile control at the Grouping station is alarming operator from pallet pair which is too wide to fit through the trailer door. Or sometimes there can be tails or ripped stretch wrapping, which can trip the sensors.
• Operator mistakes always happen. Most commonly these happen when automatic loading sequence is interrupted with manual override.
• Misalignment of the trailer
  • If the loading is always with containers and without automatic alignment, then inductive sensors are detecting that the container is close enough to LoadMatic, so that interlock can be achieved.
  • When having automatic alignment and loading both containers and trailers, container locking clamps cannot be utilized. If the trailer angle is too far off form the LoadMatic alignment range, PLC will inform that the alignment cannot be completed, and trailer needs to be re-reversed to loading position.
    • Either painted lines on the ground or optional wheel guides will help the truck driver to reverse to the loading position faster and more accurately.

• Dock levelers aren’t needed anymore, as LoadMatic is capable in adjusting the height difference of the trailers
• Depending on the size / length of the leveler, it needs to be checked whether the front legs of LoadMatic will be on top of the existing leveler.
  • It is probable, that the leveler cannot withstand the pressure what the legs are creating, so floor load has to be overcome somehow.
• LoadMatic frame adds height on top of the existing step dock height. This height difference needs to be adjusted outside the building, so that trailer floors are within operating range of LoadMatic. We are more than happy to review different possibilities on how this can be countered.
• The door opening is typically also too low and narrow to make automatic alignment possible. On this as well, we are happy to share our expertise with you on the changes