Pallet-free Production Line Layout Optimization: How Can Compact Design Improve Space Utilization by 50%?

Palletl-free Production Line Layout Optimization: How Can Compact Design Improve Space Utilization by 50%?

Abstract As the manufacturing industry transforms towards intensification and intelligence, efficient utilization of production space has become crucial for enterprises to reduce costs and increase efficiency. This paper focuses on the layout optimization of palletless production lines, proposing a systematic solution to improve space utilization by introducing a compact design concept. Research shows that through U-shaped closed-loop layout, vertical space integration, and modular cluster technology, material flow distance can be reduced by more than 40%, non-production areas can be compressed by 30%, ultimately achieving a 50% increase in space utilization. The optimized production line not only reduces land costs but also reduces energy consumption by 15%-20% and increases capacity by 18%-25% through logistics optimization. The method proposed in this paper provides a quantifiable implementation path for optimizing space resources in the manufacturing industry.

Keywords Palletless production line; layout optimization; compact design; space utilization; U-shaped layout; logistics energy consumption

1. Introduction

In the context of scarce land resources and increasingly stringent environmental protection requirements, traditional production line layouts are no longer sufficient to meet the demands of efficient and intensive production. While pallet-free technology eliminates pallet handling, most production lines still employ linear layouts, leading to fragmented space, lengthy logistics paths, and poor functional area integration. This study addresses this issue by proposing a layout optimization method centered on compact design. Through a systematic restructuring of production processes and spatial organization, it aims to achieve a significant improvement in space utilization. This paper will analyze the problem from three dimensions: theoretical framework, technical approach, and implementation case studies.

2. Spatial Characteristics and Optimization Potential of Pallet-Free Production Lines

2.1 Technical Characteristics Analysis
Pallet-free production lines eliminate traditional pallets, enabling a direct transition from block forming to curing. This transformation brings two major spatial advantages: firstly, it eliminates pallet stacking and handling areas; secondly, it shortens the distance between processes. However, existing layouts often overlook these advantages, retaining redundant buffer areas, resulting in space utilization rates generally below 65%.

2.2 Identification of Major Space Waste Sources

Linear layout leading to backflow paths: Materials need to travel back and forth between the forming, curing, and stacking areas, with an average flow distance exceeding 150 meters.

Functional area isolation: Excessive safety distances are reserved between each process, resulting in non-production areas accounting for 35%-40%.

Idle vertical space: Traditional single-layer designs result in less than 50% utilization of factory height.

3. Technical Framework of Compact Design

3.1 U-shaped Closed-Loop Layout System
Replacing the traditional straight-line arrangement with a U-shaped closed-loop structure creates a triangular synergy between the forming, curing, and stacking functional areas. The core advantages of this layout are:

Material flow path shortened to less than 90 meters, a reduction of up to 40%.

Separation of personnel and material flow lines improves operational safety.

Reserved interfaces support future process expansion.

3.2 Vertical Space Integration Strategy
Adopting a double-layer or even triple-layer three-dimensional design, while ensuring equipment maintenance space, achieves vertical synergy of "ground forming and aerial curing." Key technologies include:

Aerial erection scheme for lightweight steel structure curing kilns

Integrated application of automatic hoists and inclined conveyors

BIM-based spatial interference detection system

3.3 Modular equipment cluster design
Integrating related process equipment into standardized modules, achieving "plug-and-play" layout adjustments through flexible connection technology. Each module employs a honeycomb arrangement internally, while retaining only the minimum necessary external passageways, reducing the equipment footprint by more than 25%.

4. Implementation Path and Effect Verification

4.1 3D Simulation and Optimization Process
Based on a digital factory simulation platform, a four-step implementation method for layout optimization is established:

Current Status Modeling: Laser scanning to acquire existing layout point cloud data

Bottleneck Analysis: Identifying key constraints through logistics simulation

Solution Iteration: Generating 3-5 compact layout schemes

Virtual Verification: Simulating equipment operation, personnel operation, and emergency evacuation scenarios

4.2 Empirical Case Effect Analysis
After implementing the transformation in a building materials company in Zhejiang, the relevant indicators are compared as follows:

Indicator Item Before Optimization After Optimization Improvement
Space Utilization Rate 62% 93% +50%
Land Area 1200㎡ 840㎡ -30%
Daily Production Capacity 800 tons 946 tons +18%
Energy Consumption per Ton of Product 42.5kWh 36.0kWh -15.3%
Material Flow Distance 150 meters 90 meters -40%

4.3 Hidden Benefits Analysis

Land Cost Savings: Based on industrial land prices, annual cost savings are approximately 800,000-1,200,000 RMB.

Improved Operation and Maintenance Efficiency: Increased equipment concentration shortens inspection paths by 60%.

Retrofit Cost Recovery Period: Average investment recovery period is 14-18 months.

5. Key Technological Breakthroughs and Innovations

5.1 Space Compression Algorithm
A layout optimization model based on a genetic algorithm was developed, using minimizing material flow distance and maximizing space utilization as dual objective functions to achieve automated layout scheme generation.

5.2 Flexible Connection Technology
A rapid docking system between equipment was developed, supporting production line reconfiguration within 72 hours to adapt to multi-variety production needs.

5.3 Intelligent Scheduling System
Integrating WMS and MES systems, automatic material routing and collaborative equipment scheduling are achieved, reducing waiting time by more than 30%.

6. Industry Promotion Value and Implementation Recommendations

6.1 Applicable Scenario Classification

Category A (Priority Transformation): Enterprises with limited land in urban industrial parks

Category B (Gradual Implementation): New or expanded production line projects

Category C (Implementation Assessment): Enterprises with currently operational traditional layouts but room for efficiency improvement

6.2 Implementation Risk Control

Technical Risk: Pre-verify equipment compatibility using digital twin technology

Production Risk: Adopt a phased transformation strategy to ensure 50% continuous operation of capacity

Investment Risk: Provide various transformation packages and support financial leasing models

6.3 Standardization Promotion Recommendations

It is recommended that industry associations take the lead in formulating the "Compact Design Specification for Pallet-Free Production Lines," clarifying the calculation methods and compliance requirements for core indicators such as space utilization and logistics efficiency.

7. Conclusion and Outlook
This paper systematically demonstrates the feasibility of achieving a 50% increase in space utilization of pallet-free production lines through compact design. Research shows that the synergistic application of three major technologies—U-shaped layout, vertical integration, and modular clustering—can not only significantly save space resources but also simultaneously improve production efficiency and energy utilization. Future research can delve deeper into three directions: first, developing an AI-based adaptive layout system to achieve dynamic optimization; second, exploring ultra-high-rise vertical production line technology to further overcome spatial limitations; and third, establishing a cross-industry compact design standard system to promote the overall improvement of space utilization in the manufacturing industry. Compact layout is not only a technological innovation but also a strategic choice for the manufacturing industry to cope with resource constraints and achieve sustainable development.