Robotic Palletizing Cells

PalletPro is the perfect solution for all types of palletizing. No matter what type of product needs to be palletized, PalletPro is the perfect choice. We have developed standardized applications for automated palletizing of: sacks, buckets, boxes and beverage cartons.

Each time we start from the idea: “Everything should be easier and more efficient with PalletPro“. All palletizing applications are designed in such a way that they can be easily connected to existing factory traceability systems. The automated applications can be delivered with industrial palletizing robots from FANUC, KUKA or ABB, so that the most advantageous solution can be chosen without compromises.

PalletPro XS

PalletPro XS robotic bag palletizing system
Compact automated robotic solution for palletizing sacks. Regardless of the type of product inside the sack, PalletPro XS offers you the possibility to palletize up to 515 sacks per hour. With PalletPro XS you can palletize sacks of: sugar, flour, cement, sand or any other material. This innovative solution has been specially developed for high productivity, regardless of the weight handled. It has a wide range of optional equipment. In this way you can benefit of a perfect solution adapted to your needs.

PalletPro XG

PalletPro XG robotic pail palletizing system
The PalletPro XG pail palletizing system is suitable for production processes where product weights are 5 kg or more and high palletizing speed is required. PalletPro XG has an impressive palletizing capacity. Up to six rows of pallets can be stacked per minute. Even with products over 50 kg, the palletizing speed remains constant without affecting productivity.

PalletPro XC

carton box palletizing with Palletpro XC

End-of-line palletising with the PalletPro XC system is an advantageous solution for cardboard factories, bringing with it improvements in efficiency, safety and productivity.

Automated palletising solutions are designed to be easily adaptable to different sizes and types of cardboard. Thus, they fit the changing needs of production cardboard plants.

Also, PalletPro XC can be successfully used for palletizing boxes of water, juice or other beverages or food products.

What are robotic palletizing systems and how do they work?

Robotic palletizing systems are automated solutions that use robots to efficiently stack products onto pallets.

These systems typically consist of a robot manipulator equipped with end-of-arm tooling (EOAT) specifically designed for the product being palletized.

The robot precisely lifts and arranges products onto pallets according to pre-programmed instructions, ensuring consistent and accurate stacking.

Here is a more detailed description of how robotic palletizing systems work:

  1. Products are brought into the palletizing area on a conveyor belt.
  2. The robot picks up the first product from the conveyor belt using the gripping device.
  3. The robot moves to the pallet and places the product in the appropriate place.
  4. The robot repeats steps 2 and 3 until all products are stacked on the pallet.

See how palletizing is done with an industrial robot in this video as well.

What kind of jobs do palletizing robots do?

Palletizing robots are primarily used in industries for material handling tasks, particularly stacking and moving goods or products with efficiency and precision.

They are frequently deployed in the areas of packaging, warehousing, and production lines. Their duties include arranging, orienting, and stacking items onto a pallet in specific patterns.

These robots also perform tasks such as depalletizing, where they are used to remove items from the pallets. They can efficiently unload goods from a pallet and place them on a conveyor for further processing.

Besides these fundamental tasks, they can be customized to handle diverse items with different complexities and weights. By doing so, palletizer robots help enhance productivity and minimize human errors in industrial settings.

What are the benefits of palletizing with industrial robots?

Palletizing with industrial robots offer numerous advantages over traditional manual palletizing methods, including:

  • Increased productivity: Robots can palletize products much faster and more consistently than humans, boosting production output and reducing labor costs.
  • Improved ergonomics: Manual palletizing can be physically demanding and prone to injuries. Robots eliminate this risk and provide a safer work environment.
  • Enhanced accuracy and consistency: Robots can accurately stack products according to precise parameters, ensuring uniform pallet loads and preventing product damage.
  • Reduced errors and waste: Automated palletizing minimizes human error and product damage, resulting in fewer rejects and wasted materials.
  • Enhanced flexibility: Robots can adapt to handle a variety of product sizes, shapes, and weights, making them versatile for different applications.
  • Improved safety: Automated palletizing systems eliminate the risk of workplace injuries caused by lifting, bending, or repetitive motions.

What types of products are suitable for robotic palletizing systems?

Robotic palletizing systems can handle a wide range of products, including boxes, bottles, cans, cartons, cases, bags, pouches, and even irregular-shaped products.

The specific capabilities of a robotic palletizer depend on the chosen robot and EOAT design.

What is the difference between conventional and robotic palletizers?

Conventional and robotic palletizers vary in their functionality, flexibility and operational mechanism.

Traditional or conventional palletizers are often automated, but follow preset patterns and instructions to stack items on pallets. They lack the ability to process different product sizes simultaneously, requiring manual intervention to adjust for varying dimensions.

On the other hand, robotic palletizers utilize robotic arms with a higher degree of flexibility, capable of adjusting to different product sizes and shapes. They offer superior adaptability in handling different packing patterns, reducing the need for human intervention. 

Hence, robotic palletizers are more versatile and efficient in various production environments compared to conventional palletizers.

How to choose the right palletizing system for your application?

Several factors influence the selection of a robotic palletizing system, including:

  • Product type and dimensions: The robot and EOAT must be able to handle the weight and size of the products being palletized.
  • Production volume: The system’s throughput capacity should match the desired production rate.
  • Pallet type and size: The system must accommodate the desired pallet dimensions and configuration.
  • Factory layout and workspace: The system’s dimensions and layout must fit within the available space.
  • Safety requirements: The system must comply with industry safety standards and regulations.

What are the costs associated with robotic palletizing systems?

The total cost of ownership (TCO) for a robotic palletizing system includes several factors:

  • Hardware costs: The robot, EOAT, conveyors, and other system components.
  • Software costs: The robot controller, vision system, and other software components.
  • Installation and integration costs: The labor and materials required to install and integrate the system into the existing production process.
  • Maintenance costs: Regular maintenance and upkeep to ensure optimal system performance.

Contact us to get a quote that suits your needs.

Why choose robotic palletizing cells from INNO Robotics?

INNO Robotics, with its extensive experience as a robotic systems integrator, offers several advantages to companies considering robotic palletizing:

  • Expert consultation: INNO Robotics can help assess your specific needs and recommend the most suitable robotic palletizing system for your application.
    Our production lines automation consulting service will help you pick the best technical solution.
  • System design and integration: INNO Robotics engineers can design, integrate, and commission a custom-tailored robotic palletizing system that seamlessly integrates with your existing production process.
  • System commissioning and training: INNO Robotics will ensure your robotic palletizing system is properly commissioned, tested, and trained for your operators.
    See also our robotic cells specialized training for complete assistance.
  • Ongoing support and maintenance: INNO Robotics provides ongoing support and maintenance services to keep your robotic palletizing system running at peak performance.

How can you maximize the ROI of your automated palletizing system investment?

To maximize the return on investment (ROI), consider these strategies:

  • Optimize product flow: Design your production line to minimize bottlenecks and ensure efficient product flow towards the palletizer.
  • Implement predictive maintenance: Regularly monitor the system’s performance and perform preventive maintenance to avoid downtime and costly repairs.
    For proper and professional maintenance of your automated palletizing system, consult our robotic cells maintenance service.
  • Continuous improvement: Gather data on system performance and identify opportunities to further optimize productivity and efficiency.

What is the role of a pallet dispenser in a robotic palletizing system?

A pallet dispenser is an essential part of a robotic palletizing system. It ensures that a pallet is always available for the robotic palletizer to place products on.

Here’s how a pallet dispenser can be used in a robotic palletizing system:

  • Manual pallet placement: The least automated option is to manually feed pallets into the cell or onto an infeed conveyor one at a time.
  • Robotic pallet picking: To increase automation, cells can be outfitted with a pallet magazine that stores a number of empty pallets for the robot to pick and place automatically.
  • Automated pallet dispensing: When maximum speed and automation are required, incorporating a high-speed automated pallet dispenser is frequently the best option.

In all of these scenarios, the pallet dispenser enables operators to reload pallets without disrupting robot operations. This improves throughput and efficiency in the palletizing process.

The pallet dispenser’s role and configuration can vary depending on the requirements of the specific application.

Can a collaborative robot be used as a palletizing robot?

Yes, a collaborative robot, or cobot, can be used in a palletizing task. These robots are designed to work alongside human workers safely.

They can be an excellent choice for palletizing tasks in environments where human and robot tasks need to be integrated.

What types of palletizing robots can be integrated into INNO Robotics applications?

INNO Robotics applications can integrate a wide range of palletizing robots, such as:

  • Robotic arms with multiple axes of movement, grippers and suction cups for efficient picking and placing of items, and advanced vision systems for accurate positioning and sorting of pallets. 
  • “Gantry” robots which are designed to handle heavy loads with precision and speed, ensuring efficient palletizing of products.

Collaborative robots – for example, in a warehouse that handles a wide variety of products of different shapes and sizes, collaborative robots can be used for palletizing operations alongside human workers, offering flexible and efficient solutions.

How can you optimize the performance of a palletizing robot to increase the efficiency of the production process?

Optimizing the performance of a palletizing robot to increase the efficiency of the production process can be achieved through several methods:

  1. Improving robot programming: Make sure the robot is programmed to perform movements in the most efficient way possible. This can include reducing unnecessary movements, optimizing trajectories and ensuring effective coordination with other parts of the production line.
  2. Use of an appropriate clamping device: The robot clamping device (EOAT) must be suitable for the product being palletized. An inadequate EOAT can lead to inefficient product handling and delays in the palletizing process.
  3. Regular maintenance: Like any mechanical equipment, palletizing robots require regular maintenance to operate at maximum capacity. This may include lubricating moving parts, replacing worn parts, and checking the robot’s software for errors or updates.
  4. Performance monitoring: Uses sensors and monitoring software to track the performance of the palletizing robot. This data can be used to identify problems before they become serious and to find opportunities to improve performance.

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