The Actiw LoadMatic is a fully-automated loading system for non-modified trucks and containers, for transporting both palletised and non-palletised materials.
Below you can find out the frequently asked questions about the LoadMatic loading system.
These are split into three main categories:
General
Operational
Technical
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BOOK NOWThe materials are prepared on the loading plate, then the load is transferred into the trailer or container in a one-shot process. When the load is inside the trailer or container, the Stopper Plate then activates which secures the goods while the plate retracts.
The first LoadMatic system was supplied over 10 years ago. Since then the system has been used by some of the largest companies around the world to revolutionise their loading process. Additionally, We have installations around the globe which enables us to offer site visits to our clients to see the system in action and hear first-hand experiences of using the system.
No, you do not need to modify a trailer or container to use the LoadMatic system. This is what has made the system a favourite for companies that don't have a dedicated fleet of trailers and use third-party logistics (3PL) companies.
The LoadMatic system can load a trailer or container in less than 7 minutes. However, the time it takes to prepare the load on the loading plate will depend on your individual set-up. During a consultation, our team will be able to support you in finding the best set-up for your individual scenario.
The LoadMatic system utilises a series of sensors to align the system to the trailer or container to ensure a safe, secure and efficient loading process.
Loading inspection can be automated by utilising a series of sensors built-in to the LoadMatic system to detect things such as product damage.
The exact grade of utilisation of a trailer or container will depend upon the factors such as the type of pallet and loading pattern. During a consultation our team will be able to help find the best loading practice for your company.
The LoadMatic system will reduce the traffic at your loading dock dramatically and increases your operational safety as well as sustainability by reducing energy used in operating Fork Lift Trucks (FLTs) and Automated Guided Vehicles (AGVs). Furthermore, it will load the trailer or container in one shot which is a faster and more efficient method of loading.
Yes, we have systems being used by some of the biggest companies in the world every day to safely load trailers and containers. Our solutions are designed in accordance with the EC/2006/42 regulation for machinery safety and installation will be completed to all applicable local safety standards.
The LoadMatic system does not require any modifications to be made to trailers or containers. This is great for companies who do not own their own fleet of dedicated trailers or do not want to modify their trailers.
No, there are no civil-works required to install the LoadMatic system.
Yes, the LoadMatic system can be used for drop-off loads.
Yes, the LoadMatic system can be used in cold storage operations, as well as outdoors. Additionally, we have vast experience in providing Automated Storage and Retrieval Systems (ASRS) for cold storage operations. For cold storage applications, we add a heating system to ensure the viscosity of the hydraulic oil and to avoid condensation on sensors and the Human Machine Interface (HMI).
The 85 docks are likely a result of a required outbound capacity based on manual loading. As the LoadMatic system is capable of doing 3 loads per hour you can have the same number of trailers and containers loaded with only 28 docks. Reducing space and labour needed by just under a third.
Yes, during the loading process (around 7 minutes) an operator is required to supervise the process. However, an operator can supervise more than one LoadMatic system at a time.
The LoadMatic system can load non-palletised goods, additionally it can de-palletise the goods for you.
Thanks to our in-house Loading Plate technology, the system can still safely load cargo into a trailer or container that is reaching end-of-life.
Yes, thanks to our vast experience in warehouse automation the LoadMatic can be integrated into almost any WMS.
Yes, we have delivered multiple LoadMatic lines for loading non-palletised products on slip-sheets, such as: carton boxes.
Yes, we can ensure that the connectivity to any existing load staging system is seamless and efficient.
Yes, raw data from sensors can be collected from LoadMatic’s Programmable Logic Controller (PLC) using standard protocols. Additionally, with our software, you can filter and process the data and present it in an ideal way for tracking your custom Key Performance Indicators (KPIs).
Yes. Barcode, QR and RFID scanners can be included into the LoadMatic system in order to collect the individual product unit IDs, to be used in the shipping manifest. Additionally, this unit tracking helps to prevent shipping and other operational mistakes. The product unit ID can be compared with the pre-received shipping manifest received from your Warehouse Management System (WMS) / Enterprise Resource Planning Software (ERP), and after being loaded, is automatically removed from stock.
The load-forming process (getting the product on the loading plate) usually takes around 15 minutes, which means that it can be initiated after the truck has been confirmed on site and started the check-in process. Additionally, we offer our modular load buffering solutions, which can store anywhere between 1 and 30 full truck loads to quickly feed the correct units into the LoadMatic system when required. This buffer system in combination with LoadMatic can output up to 100 pallets per hour.
We are an independent supplier and systems integration company and regularly work with a wide range of suppliers both locally and internationally to be able to provide best-in-class solutions for our clients. We will work with customer-selected or preferred sub-suppliers to effect a solution that best suits the customer’s needs.
Product overhang is quite acceptable. In these situations, the product on the pallets' loads will be in contact, not the pallets. The LoadMatic’s low friction and low profile roller bed ensures gentle handling and that the product-to-product contact forces are typically less than compared to forklift loading or gravity lane use.
If there is variable product overhang, this can cause the total width of the load to exceed the door width of the container or trailer. When this happens the profile control system will halt the loading process so that checks and rectification measures can be taken, or the pallets in the row are moved to the ‘reject’ outfeed.
All the functions of LoadMatic are fully automated, meaning the presence of the operator is required to initiate and monitor the loading process only.
High-volume automated loading systems require the necessary infeed flow of pallets, which can be over 100 pallets per hour. The LoadMatic System, if placed on an existing dock and utilising the existing dock door, will extend into the warehouse at 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. However, with the implementation of high-volume, one-shot loading systems, you will 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 systems. This way the system and investment size can also be streamlined to have the 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 trailer or container door without issues.
Yes, our software can also be used via a tablet, and it can be viewed on internet browsers.
The profile check is the automated process of ensuring the materials will fit through the trailer or container door. 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.
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 available with the LoadMatic system. This works by the weight of each pallet being received from your ASRS/ERP system, or by integrating a pallet weighing system on the infeed conveyors.
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 Automated Trailer Loading Systems (ATLS).
The LoadMatic system will match your local electricity standards, for example: in Europe, the system requires 400V/50Hz, 3phase connection.
Depending on the configuration, the LoadMatic is spread over two or three pairs of legs. In the case that the existing floor strength is less than what is required, we are able to modify the feet of the LoadMatic to have larger surface area to distribute the pressure.
The loading door opening is recommended to be a minimum of 3x3 metres.
If the LoadMatic is designed to only load containers, we implement a supporting pin and clamping device in the front of the LoadMatic. This holds the container on the correct level during the loading process, thus preventing any sinking of the container. For trailer loading, the LoadMatic has an automatic height adjustment feature, which tracks the height movement of the trailer during the loading sequence and adjusts LoadMatic height automatically.
There are two ways this is normally handled:
With our proprietary Actiw LoadManager software, we can provide a single connection point to your system which acts as the filtering and reporting tool:
Actiw LoadManager has a 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 an integration process tool between LoadMatic system and your other systems like your ERP, WMS.
Alternatively, the system can have a direct connection with your DC's IoT platform providing the raw data from the equipment
In both scenarios, the machine data is mined directly from the Programmable Logic Controller (PLC) equipment.
Yes, multiple and different patterns are possible to use. To either maximise trailer or container utilisation or to achieve optimal weight distribution. Furthermore, different pallet sizes can be mixed in the same load.
The LoadMatic can handle a load of 30,000kg/66,000lbs as standard, however, special designs are also possible for higher loads.
Standard documentation for the equipment includes the maintenance and cleaning schedules and instructions as standard to ensure that the equipment operates for the designed lifespan of 25 years. Additionally, we have maintenance and servicing packages available, find out more by visiting our Services section.
Regular maintenance checks should be completed monthly, which includes checking chain tension and sensor positioning. For the equipment itself, no special maintenance is required apart from changing the plastic plate on the bottom.
Dock levellers are not needed with the LoadMatic system because of the auto-alignment feature. Depending on the size/length of the leveller, it needs to be checked whether the front legs of the LoadMatic will be on top of the existing leveller. If so, It is possible that the leveller will not be able to withstand the pressure that the legs will create.
Contact us today for a consultation session with a member of our Systems team.
During the consultation, a Joloda Hydraroll Group Systems Expert will speak with you about your business' current logistics operations, plans and goals.
We have over 60+ years of experience providing cutting-edge technological solutions to the logistics industry and have helped countless companies around the world lighten their load.
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