What is a box Palletizing robot?

A box Palletizing robot, also known as a robotic Palletizer, is an automated system used to stack and organize boxes onto pallets for shipping and storage. 

These robotic arms pick up individual boxes and place them onto pallets in an organized pattern. 

How do they do it? By using very sophisticated software and 3D vision systems, the robots can handle a variety of box sizes, weights, and configurations.

It’s important to keep in mind that box Palletizing robots offer a huge amount of benefits over traditional palletizing (the one you do while bending your knees). 

Just take a look: 

• You’re far more productive: Robotic Palletizers can stack up to 6 boxes per minute, outpacing human workers. This results in higher throughput and efficiency.
• You pay far less: Automating the Palletizing process eliminates the need for manual laborers to stack boxes, which cuts labor expenses.
• Things are safer. Robotics remove workers from physically demanding, repetitive tasks that can lead to injuries (just think of their backs!). Also, operators are isolated from heavy machinery and loads.
• They are very precise. Robotic arms have a high degree of accuracy, stacking boxes neatly onto pallets in consistent, stable patterns, which minimizes load shifting and maximizes pallet space.
• Flexibility (not like yoga, though): Modern box Palletizing robots are highly flexible and can handle a range of box types, sizes, and weights. You can also reprogram them to adapt to new products or stacking patterns with relative ease.

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Things to keep in mind when choosing a box Palletizing robot

There are a few things to keep in mind before you run out and invest in your first box Palletizing robot. 

Keep this list handy: 

• How much can it lift? - Make sure the robot can handle the weight of your heaviest boxes and pallets. Most box Palletizing robots can lift 20 to 100 kg.
• Can it reach far? - Double-check how high and wide of an area the robot needs to access. Longer reaches typically mean higher costs.
• Is it fast? - Faster robots can handle more boxes per minute but often come with a higher price tag. 
• Does it require a degree in IT? - Look for a robot with intuitive, easy-to-use software that allows for quick programming changes. Some offer simulation software so you can test new pallet patterns offline.
• Is it safe? - Proper guarding and safety mechanisms are necessary for most Industrial robots (except Collaborative robots, or Cobots). Make sure the robot comes equipped with features like emergency stops, light curtains, and motion control to keep your employees safe.
• Does the manufacturer offer support? - Choose a robot company that offers strong customer service and technical support in case any issues rear their ugly heads. They should be able to help integrate the robot, program new pallet patterns and perform regular maintenance.

And, of course, the cost, but we’ve left a whole section for that. 

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How much does a box Palletizing robot cost?

The cost of a box Palletizing robot can vary a great deal depending on the specific robot model and added components like conveyors or grippers. 

These are the factors to drive a robot’s cost:

• The robot arm: The robot arm itself typically ranges from $30,000 to $200,000 depending on the payload capacity, reach, number of axes, and manufacturer. The heavier-duty arms with a higher payload and longer reach will be on the higher end of that range.
• End-of-arm tooling: End-effectors like grippers, suction cups or clamping mechanisms are needed to pick up and place boxes. These can add $5,000 to $50,000 to the total cost depending on their complexity.
• Are conveyors necessary? Infeed and outfeed conveyors transport boxes to and from the robot. Conveyor costs are $10,000 to $100,000 depending on their length and speed requirements.
• Do you need safety equipment? Safety measures like light curtains, scanners, fencing and mats are necessary for any automated Palletizing system. This safety equipment typically adds $10,000 to $50,000 to the total price.
• Integration and installation: Integrating the various components of a Palletizing cell and installing the system on-site will cost between $10,000 to $50,000 depending on the complexity. Programming the robot and setting up the cell also factors into integration costs.
• Optional upgrades: Upgrades like a multi-robot system, custom grippers, or pallet dispensers and conveyors can increase the cost by $10,000 to $200,000.

So, depending on whether you go with a typical industrial robot or a Collaborative robot that doesn’t require external safety measures, you can expect to budget between $50,000 to $500,000.

Top 3 box Palletizing Robots for 2024

Time to bring out the big guns – and by that we mean robotic arms! These Palletizing robots excel at stacking and organizing boxes onto pallets for shipping and storage. They are fast, precise, and can outlift Schwarzenegger himself.

Check them out: 

RO1 by Standard Bots

Standard Bots' American-made RO1 is making waves in the Palletizing world with its impressive features that scream “ease of use.” 

With a darn fine 18 kg payload capacity and an extended reach of 2.4 meters, RO1 excels in handling a wide range of palletizing tasks with a huge operational efficiency. 

Enhancing the appeal, RO1 integrates advanced technology, such as a high-level AI, built-in camera, and vision system, to give you picture-perfect product recognition and placement

Moreover, RO1 is a Cobot, meaning you don’t have to invest in safety barriers. It can operate safely alongside human workers.

The cherry on top? The robot's plug-and-play design simplifies installation and integration into existing workflows and requires absolutely zero coding expertise. 

And if you think that this kind of performance means “goodbye to your piggy bank,” there’s good news. RO1 is a cost-effective solution for businesses big and small looking to enhance their automation capabilities without overspending, starting at half the price of the competition.

And if even that’s too much, you can lease it for $5/Hr. 

FANUC M-20iA

Coming in hot is FANUC and their M-20iA model, an excellent box Palletizing robot 

It can lift 7-35 kg (depending on the model) and has a reach of up to 2.2 meters. The M-20iA has advanced force control, which lets it handle boxes gently and place them precisely on pallets. 

It is a fast and durable Industrial robot that can achieve up to 120 picks per minute. FANUC also offers a full range of software and safety equipment for integration.

But, there’s a high price variability depending on the model you want: 

• M-20iA/12S to M-20iA/20L: $30,000 - $40,000
• M-20iA/35T to M-20iA/400T: $40,000 - $55,000
• M-20iA/700L: $55,000 - $70,000

ABB IRB 6640

ABB's big boy IRB 6640 is a high-speed box Palletizer capable of over 180 picks per minute.

It has a super-high payload of up to 300 kg (depending on the model) and a reach of 2.55 meters, allowing it to stack heavy boxes higher and in more complex patterns. 

The IRB 6640 uses ABB's best-of-the-best motion control for extremely smooth and accurate movement. 

Plus, it comes pre-engineered for Palletizing applications but can also be customized for others. 

But, it will cost you, with ballpark estimates for pricing going as far as: 

• 140-170 kg: $35,000 - $50,000
• 200-235 kg: $45,000 - $60,000
• 300 kg: $55,000 - $70,000

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FAQs

How fast can a box Palletizing robot work?

Box Palletizing robot speed depends on the model and specifications, but many can palletize up to 2,500 boxes per hour. ‍

The speed is also affected by factors like box size, stacking pattern, and conveyor speed. Faster robots allow for higher throughput but often at a higher cost.

How much space does a box Palletizing robot require?

The space required depends on the robot model and any additional equipment like conveyors. In general, you'll need at least a 10 x 10-foot area for a compact box Palletizing robot workcell.

More complex systems with multiple conveyors and pallet dispensers will require a larger footprint, up to 30 x 30 feet.

The robot arm itself only takes up a few square feet, but you'll need space for boxes, pallets, and maintenance access.

What level of expertise is needed to operate a box Palletizing robot?

Box Palletizing robots are designed to require minimal operator intervention.

They can often be set up and programmed by someone with basic technical skills and on-the-job training. Once programmed, the robots can run automatically with periodic supervision and maintenance.

Some troubleshooting may require an engineer, but many issues can be addressed remotely.

What is the payback period for investing in a box Palletizing robot?

The payback period for a box Palletizing robot depends on factors like initial cost, labor and production costs, efficiency gains, and throughput.

On average, the payback is between 18 months to 3 years. Box Palletizing robots significantly reduce labor costs and improve productivity, with many customers reporting 50-70% lower costs and 2-3 times higher throughput after installing a robot.

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Summing up

You've got the lowdown on the top box Palletizing robots of 2024. Now, it’s up to you to choose the right 'bot for your operation's needs. 

But, whichever model you choose, you can’t go wrong; now it’s just a matter of assessing your operational needs, budgeting smartly, and reaping the benefits of automation!