Top 5 FAQs about palletizing: What manufacturers need to know

Palletizing is a critical end-of-line process, but it’s also one of the most physically demanding and complex tasks in a factory. From manual stacking to advanced robotic systems, manufacturers often have questions about which solution fits their operations. Here’s a practical guide answering the top five FAQs about palletizing.

1. What’s the real cost of palletizing automation?

The cost of automation isn’t just the hardware; it’s a strategic investment in efficiency, consistency, and scalability. Key cost considerations include:

• Cobot arm: The main hardware.
• End-effector: Grippers or suction cups for handling products.
• Integration & setup: Conveyor adjustments, electrical work, and line modifications.
• Software & programming: Intuitive or custom interfaces to run your application.
• Custom engineering: Complex projects may require specialized tooling or expert designers, increasing costs.
  
  

Lean Palletizing Advantage:
PAL Ready is production-ready on day one, with smart infeed, mobility features, built-in safety scanners, and adaptive grippers—delivering fast ROI without the headaches of engineering or programming delays. PAL Series provides modular scalability for growing operations.

ROI Example: Most Lean Palletizing customers recover their investment in 1–2 years through reduced setup time, consistent uptime, and simplified maintenance. Glenhaven Foods reduced operator strain, maintained consistent throughput, and achieved ROI in just 13 months, while employees could focus on higher-value tasks.

2. How do I fit a palletizer into a real-world factory?

Space is often the biggest barrier to automation. Many facilities weren’t designed for robotics, which is why compact solutions like PAL Ready matter:

• Footprint: About half a pallet: it fits into tight lines without reconfiguring your floor.
• Modular & mobile: Can be relocated between lines or seasonal setups.
• Safe & accessible: Built-in safety scanners maintain visibility and workflow efficiency.
• Pre-assembled: Deploy on day one with minimal installation effort.

Example: Panovo, a snack and frozen bakery producer, deployed five PAL Series cells in limited space. They achieved reliable, consistent stacking, even in low-temperature environments, without expanding their footprint.

3. Which palletizer is right for my factory? 

There’s no one-size-fits-all answer. The best solution depends on your throughput, space, budget, and flexibility needs. Here’s a quick overview:

• Engineered centralized palletizers: High-volume, multi-line facilities; large footprint; long ROI; 30–80 cases/min.
• Engineered end-of-line robotic palletizers: High-capacity single lines; durable and reliable; 25–60 cases/min.
• Engineered end-of-line cobot palletizers: Flexible, space-efficient; safe for operators; 8–15 cases/min
• Plug-and-play “In-a-Box” palletizers: Compact, fast installation; moderate throughput; limited customization.
• Lean Palletizing (PAL Ready / PAL Series): Mid-volume, high-mix operations; quick deployment; scalable; predictable 1–2 year ROI.
  
  

Key factors to consider: throughput, available floor space, budget, frequency of SKU changes, and safety/ergonomics. Tools like the Robotiq Palletizing Fit Tool can help simulate your cell, calculate ROI, and plan your setup.

4. Can automation improve safety while maintaining productivity?

Yes. Manual palletizing carries high ergonomic risks: lifting, bending, twisting, and repetitive motions can lead to injuries, fatigue, and downtime. Collaborative cobots like PAL Ready are designed to work safely alongside humans:

• Built for collaboration: Force and speed limits, contact sensors, and rounded edges protect operators.
• Compact and contained: Clearly defined operational zone reduces hazards.
• Smart controls: Predictable motion, pre-programmed recipes, intuitive interface.
• Compliance: Meets ISO/TS 15066 standards for collaborative operation.
  
  

Real-world impact: At RAIN Pure Mountain Spring Water, operators were lifting 30 lb boxes in a compact facility, causing fatigue and turnover risk. After implementing Lean Palletizing, cobots handled the heavy lifting, while operators focused on higher-value tasks. Throughput increased, ergonomic risks decreased, and team satisfaction improved.

5. How can I scale and future-proof my palletizing operations?

Flexibility and scalability are key. Lean Palletizing solutions are designed for growing operations:

• PAL Ready: Pre-assembled, high-mix palletizing in a compact footprint. Ideal for fast deployment and seasonal/contract lines.
• PAL Series: Modular, configurable, and scalable to multi-line or multi-site setups.
• Smart software: Material Handling Copilot allows operators to run multiple SKUs without programming expertise.
• ROI-focused: Fast deployment, reduced downtime, and predictable payback periods make scaling simpler and more profitable.
  
  

By standardizing on adaptive cobot hardware and intuitive software, manufacturers can replicate successful cells across lines, reduce integration time, and avoid costly custom tooling.

Take the next step

Choosing the right palletizer doesn't have to be guesswork. With the Robotiq Palletizing Fit Tool, you can:

• Validate your application in minutes
• Generate a custom 3D simulation of your palletizing cell
• Calculate ROI and payback period with your real production data
• Receive a detailed report to share with your team
  
  

Whether you want to protect your workforce, maximize throughput, or scale with confidence, Lean Palletizing offers a practical, factory-friendly approach to end-of-line automation.