End-of-line palletising is one of the most common places to put a robot to work. It's repetitive, heavy and hard on people's backs, and it often holds up the whole line. This guide covers when robotic palletising makes sense, what's involved, and what to think about before you buy.
Why businesses automate palletising
- Labour: frees people from repetitive lifting for better jobs on the line
- Injuries: reduces manual handling strain and injury claims
- Capacity: runs consistently across every shift, including nights and weekends
- Quality: neat, consistent, stable pallets that travel better
What decides whether it stacks up
- Rate: cases, bags or bundles per minute, now and in the future
- Product: weight, size, packaging type and how many variations
- Shifts: the more hours the line runs, the faster the payback
- Floor space: room for the cell, guarding, infeed and pallet stations
- People: how many operators palletising takes today, and their injury history
Industrial robot or cobot?
Industrial robots handle higher rates and heavier loads, and sit inside a guarded cell. Collaborative robots (cobots) are slower and lighter-duty, but take less space and simpler guarding. Both still need a risk assessment. The right choice comes down to rate, weight and space.
What a palletising cell includes
- The robot, gripper and controller
- Infeed conveyor with case orientation and accumulation
- Pallet and slip-sheet handling, and pallet removal
- Guarding, interlocked doors and light curtains or scanners
- Integration with stretch wrapping, labelling and your line controls
- Operator screen for recipes, pallet patterns and changeovers
Safety
Robot cells are designed to ISO 10218 and AS 4024. That means a risk assessment, guarding positioned at the right safety distances, safety-rated interlocks, and muting or zone control where pallets enter and leave. Safety is designed into the cell from the start, not added at the end.
How a project runs
- Site review. Measure the rate, products, space and line interfaces.
- Concept and simulation. Cell layout, pallet patterns and cycle-time check.
- Design. Mechanical layout, electrical design, safety system and controls.
- Build and test. Panels built and tested in our Griffith workshop.
- Install and commission. Installation, safety validation, recipes and operator training.
- Support. Remote and on-site support, spares and new pallet patterns as products change.
How AMC helps
AMC designs and integrates robotic palletising cells, from concept and safety design through to commissioning, and integrates them with your existing conveyors, PLCs and safety circuits. We deliver in the Riverina and Australia-wide.
FAQs
Common questions about robotic palletising
Is robotic palletising worth it for a smaller plant?
Often, yes. The main factors are how many cases or bags you palletise per shift, how many people it takes, injury risk from repetitive lifting, and how many shifts you run. A site review gives you a realistic cost and payback for your line.
Can one robot handle more than one product or pallet pattern?
Yes. Robots are programmed with multiple pallet patterns and product recipes, and changeovers can be selected by the operator. A single robot can often serve more than one line.
What safety is needed around a palletising robot?
Industrial robot cells need guarding designed to ISO 10218 and AS 4024, typically fencing with interlocked doors and light curtains or scanners at pallet entry and exit points. Collaborative robots need a risk assessment too, and are generally slower and limited in payload.
Should I use a collaborative robot (cobot)?
Cobots suit lower speeds, lighter products and tight spaces, with simpler guarding. Industrial robots suit higher rates and heavier loads. The right choice depends on your case rate, product weight and floor space.
What else needs to be considered besides the robot?
Infeed conveyors, case orientation, pallet and slip-sheet handling, pallet removal, stretch wrapping, labelling, and integration with your existing line controls and safety system.
Can you integrate the robot with our existing line?
Yes. AMC designs the cell, safety system and controls, and integrates the palletiser with your existing conveyors, PLCs and safety circuits.
Next step
Got a plant, machine or board that needs sorting?
Send us the scope, drawings or a few photos. An engineer reads every request and comes back within one business day with next steps and a clear, upfront price.