Robotic Palletizer Systems: How Do They Work Differently?

Robotic Palletizers are designed to handle different types of palletizing tasks. Some systems lift products one by one, some handle full layers, and others allow multiple robots to work together to stack products of different sizes on the same pallet. Let’s look at the four main systems.

Pedestal System

A robotic arm with 4–6 axes mounted on a base. The number of axes determines its flexibility. A 4-axis arm can rotate around the base, extend, pick and place products, and rotate them as programmed. It can handle multiple lines at once and manage products of different types. Load capacity ranges from a few kilograms up to over a ton.

The process is straightforward: pallets or slip sheets are placed in a designated area, while products move along a conveyor until they reach the pickup point. The robot’s end effector, designed for the specific task, picks single or multiple items and places them onto the pallet according to the programmed pattern. Each layer can be arranged differently for stability.

The Pedestal system has limitations in workspace and size but is cost-effective and fast. A single robot can service up to four pallet positions, and the end-of-arm tool (EoAT) can be customized for different product types.

Gantry System

Built with two pillars and a beam, the robot is suspended from the structure and moves back and forth along the beam. The arm moves vertically to lift products. Depending on its axes (2–4), it can move linearly, across planes, and rotate products. This system can lift very heavy loads, single items, rows, or multiple rows simultaneously. However, it is slower. Gantry systems are usually designed for specific applications with space allowances for flexibility, enabling multiple pick-and-place points.

Layer Forming System

Uses multiple robots working together. One robot arranges and rotates products on a conveyor to form a complete layer. Once the layer is ready, another robot lifts the entire layer and places it on the pallet. This approach improves layer stability and stacking precision.

Mixed Case Configurations

Designed to palletize products of different sizes and shapes onto the same pallet. Robots ensure stable stacking by arranging each layer properly. Methods include mounting pedestal robots on rails to serve multiple pallet positions, or using multiple conveyors to deliver and orient products before a robot places them onto the pallet.

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