What Is an Automatic Palletizer? Benefits, Types & How It Works

What Is an Automatic Palletizer?

An automatic pallet stacker is an industrial machine designed to automatically stack and organise products onto pallets for storage or transportation. This equipment is widely used in the manufacturing, warehousing, and logistics industries. It streamlines the packaging process at the end of the production line by replacing manual pallet stacking with robotic or mechanical systems. These machines bring consistency, speed, and reliability to the entire production process, replacing monotonous manual labour with the precision of advanced robotic technology.

How Does an Automated Palletizer Work?

Robotic palletizing uses robotic arms equipped with specialised end-of-arm tools (EOAT) to pick up products from a conveyor belt or production line and place them on pallets in a predetermined pattern. This process typically involves several key steps:

1. Product identification and positioning: Advanced vision systems or sensors can identify the size, shape, and orientation of products entering the conveyor belt.

2. Picking: The robotic arm uses its EOAT to grasp and lift products from the conveyor belt, ensuring a secure grip to prevent damage during handling.

3. Layered stacking: The robotic arm or mechanical pusher stacks items layer by layer.

4. Pallet handling: Completed pallets can be transported to designated storage or shipping areas using automated guided vehicles (AGVs) or autonomous mobile robots (AMRs).

Types of Automatic Palletizers

Automatic palletizers come in various types, each suited for specific application scenarios:

1. Traditional palletizers: Utilise mechanical components to achieve high-speed, high-output operations. Suitable for products with uniform specifications such as cardboard boxes or containers.

Traditional palletizers are divided into low-position (ground-level) palletizers and high-position palletizers. Each type of palletizer has distinct technical features and specific applications, offering significant benefits to a wide range of industries and businesses.

2. Robotic palletizers: The most common configuration is the robotic palletizer, positioned between the pallet distributor and conveyor belt, using robotic arms equipped with grippers or vacuum cups. These systems are flexible and space-saving, ideal for mixed loads and diverse product types.

3. Hybrid Pallet Palletizer: Combining the features of robotic systems and traditional systems to achieve maximum efficiency and flexibility. Hybrid palletizers offer exceptional flexibility, speed, and reliability, making them a popular choice in manufacturing.

Key Benefits of Automated Palletizing

Implementing an automated palletizing system offers numerous operational advantages:

1. Increased throughput

Automate repetitive tasks for faster, more continuous operations.

2. Improved safety and reduced labor costs

Safety is paramount in any manufacturing environment. Automating repetitive and physically demanding tasks on the production line reduces workplace injuries and labor costs. Workers can now focus on value-added tasks such as operating equipment and assembly lines.

A recent study found that up to 24% of male warehouse workers suffer from lower back pain. Automation can help prevent this. 

3. Flexibility and scalability

Modern robotic palletizing processes are designed with high adaptability and flexibility in mind. Most automated palletizers can handle products of various types, sizes, and packaging configurations, easily adapting to production changes or multiple product types. This flexibility is crucial for businesses to quickly adapt to market demands without making significant changes to their palletizing systems.

4. Space Optimisation

Manufacturers can create automated palletizing systems to optimise space in warehouses and distribution centres. Robotic arms can stack pallets more efficiently, maximising vertical space. They can also stack pallets more densely and stably, reducing the total floor space required for storage.

5. Data-Driven Decision-Making

Some automated packaging systems are equipped with advanced sensors and software that provide real-time operational data. This data can be analysed to gain insights into production efficiency, equipment performance, and overall supply chain dynamics. This information enables businesses to make manufacturing process decisions based on data, driving continuous improvement.

6. Consistency

Humans are prone to errors, but automated systems offer unparalleled precision and consistency. Goods are precisely organised, reducing stacking errors and ensuring each pallet is evenly loaded. This precision is critical for enhancing productivity and delivering products to customers faster. 

Factors to Consider When Selecting a Robotic Palletizer

Some factors to consider when selecting a palletiser include:

1. Pallet Configuration

Pallet configuration plays an important role in determining the optimal system. Configuration aspects may include:

• Layer configuration on the pallet
• Total number of layers on the pallet
• Whether the application uses sliding trays or layered trays
• Rotation of each layer configuration

2. Additional Equipment

In addition to the palletizing machine, other equipment may be required to transport pallets, such as pallet handling robots (AGF, AMR, etc.).

3. Throughput

Consider how many items need to be palletized per minute. You should also consider the type, shape, and weight of the packages the system needs to handle.

Applications Across Industries

Automated palletizers are widely used in:

• Food & Beverage
• Consumer Packaged Goods (CPG)
• 医薬品
• Automotive Parts
• E-commerce Fulfillment

結論

An automated palletizer is a smart investment for manufacturers and logistics providers aiming to optimize their end-of-line operations. Whether you choose a robotic or conventional system, palletizing automation delivers long-term value through greater productivity, lower costs, and consistent output.

After stacking is complete, the goods still need to be transported to the correct location. This is where AiTEN's automated forklift robots come in, capable of handling different types of pallets to help businesses complete the ‘last mile’ of goods transportation.

Need help selecting the right material handling robot? Contact our experts to tailor a solution that meets your business needs.