Robotic Palletising

We design robotic palletising systems for outstanding palletising robots performance

Are you looking for Palletising Robots to speed up the Process?

Phoenix provides customised robot system whether you are looking for a single robotic palletising cell or multi-line robot palletising cell. Furthermore, we can also integrate palletising machining such as pallet grippers, cell safety equipment, such as guarding, sensors, and additional I/O on the control panel of the robot where needed.

We also work with reputable palletising system suppliers for more efficiency on conveyors. However, if you are not sure how much a palletising robotic cell costs, please click on our Robotic Calculator to have an idea of the costs.

TOP 3 Main Advantages of Palletising Robots

Robotic palletising
Standard six axis robot

There are a number of advantages in using an industrial robot for  palletising system:

  1. First, as mentioned above this is a highly repetitive task that is very tiring for a human worker. The human worker building up products onto a pallet will require numerous breaks.  On the other hand, the robot will be able to work 24 hours a day, 7 days a week if necessary.
  2. Second, the industrial robot can lift much higher weights than a human workers. The recommended maximum weight for a human worker is 25 kg.  Bear in mind that this reduces when the movements require the arms to be outstretched in the case of building up large pallet formations. However, the industrial robot can work with payloads up to 1000 kg, if necessary. Although the most common robot types for palletising tend to use robots with a payload capacity of around 180 kg. In this case, it’s usually the required reach that dictates the robot size rather than the payload.
  3. Third, the industrial robot has a much greater palletising speed than a human can achieve. So, the cycle time between a product being picked up and placed. As well, the robot returning to the pick position will be shorter than that which a human can achieve.

Main Elements of the Palletising Robot Cell

Types of Robots for Palletising

There are two different types of robots most often employed for palletising cells:  (1) the standard robot and (2) the dedicated four-axis robot for palletising operations.  Having talked about the advantages and different robot types let’s have a look at the main elements that make up the majority of robotic palletising cells.

First, we have the robot itself. Considerations here are for payload, envelope, and cycle time. In terms of the payload, this will be the maximum weight that the robot can handle.

The total payload will be the weight of the product plus the weight of the gripper. The robot payload will need to be greater than the combined weight of the product and gripper. Also, it will need to be borne in mind that if the centre of gravity is offset from the centre of the mounting flange this will reduce the payload capacity of the robot.

palletising system

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Dedicated four axis palletising robot

In the case of the dedicated palletising robot there are only four axes as opposed to six. This means that the tooling is limited in orientation to rotation solely around the vertical axis of the gripper.

However, the majority of palletising operations do not require any tilting of the product.  It means that the advantage in using a dedicated palletising robot will be that the robot speed will generally be quicker and hence a reduced cycle time.

Palletising system
Dedicated four axis palletising robot
Control Panel Phoenix

Robot Control Panel

To control the complete cell a safety panel with cell control pushbuttons will be installed which is electrically connected to the robot controller. This panel will include the safety relays for the two safety circuits for the robot and any ancillary equipment.

One circuit will be for the Estops, these will stop the robot in all modes. The second circuit will be for the cell access and this will stop the robot and spindle whenever the robot is running in Auto mode.

Palletising Cell Design

The robot cell will also need some form of guarding which will form an enclosure to make sure that nobody is present whilst the robot is working in automatic.

The usual layout for a palletising cell is to have two pallet locations with the robot in the middle of the two. The robot will palletise to one side and once completed will move over to palletise the second side. Whilst the robot is working on the second pallet the first pallet is removed and replaced with a new empty pallet.

Each of the pallet stations will have two sets of light curtains to protect the operator. The front light curtain will be active and the robot sidelight curtain muted whilst the robot is working on that station.

If the operator were to try and enter the cell the active light curtain will stop the robot.  In the case of a completed pallet, the operator will select to enter the station and this will activate the light curtain on the robot side.

It mutes the light curtain at the entrance to the station allowing the operator to enter without interrupting the sequence.  Even so, if for any reason the robot tries to enter the station during this time the active light curtain will detect the intrusion and stop the robot.

robotic cell
KUKA Robots

Palletising Robot Gripper

Fitted to the robot will be some form of gripper for picking up the product. There are different types of grippers depending on the product and the required stacking pattern.

In the case of a pneumatic finger type gripper, this will open around the product and have fingers that close to clamp the product to stop it from moving during the movement of the robot.  However, when using this type of gripper you must consider the stack pattern.  Why? Because at the moment of placing the product the gripper will open and push any product that is already palletised.

Usually, when using this type of gripper the product is released above its position in order that the gripper has room to open.

Vacuum System for Palletising


An alternative solution is to use a vacuum system rather than fingers for picking up the product. In this case, the product is held in place by an array of suckers which usually grip the product from its upper surface.

This system has the advantage that tight stacking patterns can be produced allowing the products to be placed up against products already on the pallet.

Conveyor System for Palletising

factory robots

The product will normally be delivered to one or more pickup points usually in the form of a conveyor.

Therefore, the robot requires a separate PLC to manage the conveyor.  This PLC will be part of the machine that is manufacturing or bagging the product.

The interface between the robot and the conveyor is simply the detection of the absence of the pick point being vacant with a combination of the robot clear signal and product present detection.

Robotic palletising cell design

Phoenix provides a complete turnkey solution for palletising robot cells. We work together with all robot manufacturers such as KUKA, ABB, AND FANUC just to mention a few.


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Turnkey Industrial Robot Solutions

Phoenix integrates and installs complete robotic milling solutions from initial design and consultation to manufacture. Also, we offer robot trainingrobot programmingrobot simulation, commissioning, and technical support. Whether you decide to configure your complete milling robot cell, around a new robot or reconditioned robot.