Robotic palletizing continues to transform logistics and production processes across industrial sectors. Automating this end-of-line process is proving to be a transversal solution, helping companies increase productivity, reduce physical strain on workers and minimise errors.
At ESI Robotics, we have been implementing automated palletizing systems tailored to each client's specific needs. In this article, we present three real case studies that demonstrate the direct impact of robotic palletising on business productivity and competitiveness.
Robotic palletizing involves the use of industrial or collaborative robots to organize and stack products onto pallets automatically. These systems replace or complement manual labor, ensuring greater speed, consistency, and safety.
Key benefits of automating this process include:
- Reduced cycle times
- Fewer musculoskeletal injuries and improved workplace safety
- Increased production capacity
- Better pallet space utilization
- Flexibility to adapt to production changes
- Mitigation of labor shortages
Today, robotic palletizing is accessible to companies across all industries. It’s no longer exclusive to large manufacturing plants with high production volumes. The growing need for efficiency has led more businesses to adopt automated palletizing systems.
At ESI Robotics, we design and deliver flexible, scalable palletizing solutions tailored to each client’s specific requirements, regardless of sector. Below, we present three real-world case studies that demonstrate the tangible impact of robotic palletizing in diverse industrial environments: the printing industry, the chemical and detergent sector, and the food industry.
At Corex, the manual palletizing process required intense physical effort, involving repetitive movements and heavy lifting. This posed significant ergonomic risks for workers, increasing the likelihood of injuries and resulting in more frequent medical leave. Additionally, the company faced difficulties in finding available labor, which limited its ability to scale production and meet deadlines and order volumes.
ESI Robotics developed a pioneering robotic cell for palletizing cardboard tubes, designed to meet the specific production needs of Corex. The solution ensures precision, consistency, and high efficiency. The robotic cell handles various tube sizes and references, performing palletizing in either a vertical or horizontal position across three different palletizing points. Additionally, the robot’s custom gripper uses a vacuum system to place separators between product layers.
This automation project was designed to palletize two types of milk powder bags—10 kg and 25 kg—each with unique handling and stacking requirements. This level of flexibility was achieved by developing a multi-function gripper, allowing the robot to adapt automatically to each bag type. The gripper integrates three gripping technologies: vacuum, forks, and clamps, ensuring precise and secure handling throughout the process.
The result was a highly efficient robotic palletizing system, improving both the client’s productivity and working conditions for operators.
In this project, operators are still part of the line, responsible for placing products into boxes and feeding the box-sealing machines. Once the box is sealed, it moves along motorized conveyors to the final position. There, an industrial robot detects the presence of the boxes, picks them up, and places them on pallets.
The robot alternates between two conveyor belts and transports boxes to the nearest of three pallet stations.
These three case studies clearly demonstrate the versatility and adaptability of robotic palletizing, which is transforming multiple industries by delivering measurable benefits in productivity, safety, and ergonomics.
At ESI Robotics, we design tailor-made solutions focused on the specific reality of each client and the unique challenges of their industry.
Looking to automate your palletizing process? Get in touch and discover how we can make your production more efficient and safer.
