Some problems don’t show up in your Overall Equipment Effectiveness dashboard—but they cost you big. That’s what a sauce and spice manufacturer in Latin America realized when ergonomic injuries and insurance premiums started piling up. Their answer? A fast, simple palletizing solution built to deliver ROI beyond just labor savings.

Why automate?

The team was facing more than just a labor shortage. Workers were reporting back injuries from repetitive lifting, and insurance costs had spiked. That’s when the project manager got serious about change.

Their goals were clear:

• Reduce workplace injuries
• Lower insurance premiums
• Improve end-of-line productivity

What made this a good fit?

They looked at several options—including traditional system integrators. But when they compared installation time, usability, and long-term flexibility, a Robotiq Palletizing Solution stood out.

✔️ Installed in a couple of days
✔️ Programmed by the in-house team
✔️ Low maintenance, scalable setup
✔️ No vendor lock-in

Unlike custom setups that require weeks to integrate (and constant calls to your integrator for changes), our solution gave them full ownership—without complexity.

From Costa Rica to Colombia: scalable impact

The manufacturer has two facilities—one in Costa Rica and another in Colombia—with boxes ranging from 8 to 17 kg. Even in regions with lower labor costs, the math checked out. That’s because ergonomic risks don’t care about minimum wage, and insurance companies don’t either.

The facility in Costa Rica installed a PE20 system. In Colombia, they opted for a smaller payload. In both cases, the Robotiq Palletizing Solution delivered quick wins—and sparked interest in expanding to more lines.

Takeaways for other manufacturers

Whether you're in Costa Rica or Kansas, the logic applies:

🔍 Ask the right questions.
Are you paying more for insurance? Losing time to injury-related downtime? These “hidden” costs often make or break the ROI.

🚀 Start small.
One palletizer is all it takes to show the value—and build internal buy-in for more.

🔧 Choose a solution that puts you in control.
Look for modular, open systems that your team can adapt without expert help.

And if you’re running a facility where your team is your greatest asset, you might find that the business case for automation is stronger than you think. For in-depth insights on the toll manual palletizing can take on a company and how automation can alleviate those strains, download our Manual Palletizing Ergonomic Risks ebook by industry expert, Carla Silver.