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A Case Palletizing robot is an automated robotic arm that stacks cases onto pallets for shipping and storage.
These nifty robots pick up individual cases and place them onto pallets in a precise pattern to maximize space.
Case Palletizing robots can handle a variety of case sizes at high speeds, stacking up to 30 cases per minute – and sometimes more.
Case Palletizing robots are fast, consistent and extremely precise. Their robotic arms can quickly pick up cases, rotate, and place them onto pallets in the optimal position and pattern.
They are designed to handle high throughput, stacking case after case at a breakneck pace (if they had necks, that is).
These robots also place each case with pinpoint accuracy to maximize pallet space.
Automated Case Palletizing robots help reduce worker injuries associated with repetitive manual stacking.
They also lower labor costs since fewer workers are necessary. Robots can operate on and on without stopping, so they increase productivity and cut down downtime to near zero.
Case Palletizing robots are customizable to handle different case and pallet sizes.
They’re also extremely durable and designed to operate non-stop in the most demanding warehouse environments.
Many can work 24 hours a day, 7 days a week stacking up to 30,000 cases in a single shift. That’s the kind of stacking not even Popeye could match.
There’s no one-size-fits-all price tag.
The cost depends on factors like the size and speed of the robot, the complexity of the Palletizing pattern, and any additional equipment needed.
But, as a rule of thumb, you can expect to pay between $50,000 to over $500,000 or more for a complete Palletizing cell.
The robot arm itself typically makes up a large portion of the total cost.
Arms with more reach, payload, and speed generally come with a higher price.
For most case Palletizing applications, a mid-sized arm with a 10-30 kg payload capacity and 2-3 meter reach should suit your needs well for $25,000 to $100,000+.
You’ll also need end-of-arm tooling like grippers to pick up the cases.
Vacuum grippers are a popular, low-cost option for handling cardboard cases, for instance.
Expect to pay $5,000 to $15,000 for a set of grippers.
Safety equipment like guarding, scanners, emergency stop buttons, and light curtains is required for any Industrial robot system – save for Collaborative robots or Cobots, which can work alongside humans.
This additional equipment usually adds $10,000 to $30,000 to the total cost.
Integrating the robot, tooling, and safety equipment and programming the Palletizing sequences necessitates some engineering expertise.
Most Palletizing cells are custom-designed for a specific product and production line.
These integration and programming services typically cost between $20,000 to $50,000.
Keep in mind that state-of-the-art Cobots don’t need any coding knowledge.
Not so fast! Before you make a purchase, it’s important to have a checklist that gives you an idea of what a “good” robot looks like. Otherwise, you could end up making a sizable investment that’s all expenditure, and no profit, if you catch our drift.
Check it out:
As we’ve established, Case Palletizing robots can go for a pretty penny.
When everything is said and done, be ready to pay between $50,000 to $500,000 or more for a robot that can handle your throughput needs.
Also remember to factor in additional costs like programming, installation, and ongoing maintenance.
While robotics can save money in the long run, the initial investment can cost you. But, robots tend to pay for themselves in 1-3 years, so there’s that.
Case Palletizing robots tend to need a large footprint, so make sure you have enough floor space for the robot, conveyors, and pallet stacks, if necessary.
Give some thought to how the space will impact your facility layout and workflow. The robot will also need a lot of wiggle room for loading and unloading cases and pallets.
Think about how it will interface with your existing equipment – if at all.
Go for a robot that can handle your daily case volume with room for future growth.
Case in point: most standard Palletizing robots can stack 10 to 30 cases per minute. But, there are faster, high-volume versions available as well.
Think hard about how the robot’s speed and capacity will impact your overall production goals and targets.
Ease of programming and implementation can make or break a rising automation effort.
Some robots have intuitive touchscreen programming with no code required, while others require complex coding that’s best left to experts.
Think about who will be responsible for programming and maintaining the robot.
Look for a robot with features like collision avoidance, restricted space, and motion control to keep people safe.
For Industrial robots especially, proper guarding is critical, while Cobots are much safer and can be integrated close to humans.
Now, time for the main course. Stop your search, because these are the best 3 case Palletizing robots in 2024:
Unlike some competitors, RO1 doesn't require complex ROS configurations or expensive programming software.
Instead, it has an intuitive no-code interface allowing anyone, regardless of coding experience, to set up and redeploy RO1 quickly and efficiently.
RO1 also packs a major punch in terms of power and precision. This Six-Axis Cobot outshines competitors with its superior payload capacity of 18 kg, joint speed of,435° /s, and a repeatability of+/-0.025 mm.
It can effortlessly lift heavier blanks, move faster with minimal errors, and seamlessly integrate with various grippers, conveyors, and additional features, which makes it extremely flexible and versatile.
Also, RO1 is significantly more cost-effective than its competitors, going for half the price of any robot in its class.
It even comes equipped with an onboard camera system and state-of-the-art AI (comparable to GPT-4) with self-learning capabilities.
Finally, with built-in collision detection and force-limiting, RO1 can safely work alongside humans in most Palletizing applications, so you don’t need any extra safety precautions.
FANUC should need no introduction in the Palletizing world, and the FANUC M-410iC/185 is a formidable player in this arena.
It lifts the game with an 185 kg payload capacity and stretches its capabilities with a reach of approximately 3 meters, tackling a broad spectrum of case sizes without breaking a sweat. (Primarily, because it can’t sweat, that would be expensive)
This robot is also supported by FANUC's integrated vision systems and user-friendly HandlingTool software, making programming easier than what you typically see with industrial robots.
The only setback? A price that exceeds $100,000 for most Palletizing applications.
Are all Industrial robots expensive? The YK400XG SCARA begs to differ, as a "low-cost, high-performance" model.
It’s designed for the quick and precise handling of lighter loads, it boasts a 4 kg payload and a pretty nimble reach of 600 mm, making it an ideal candidate for quick-paced, smaller-scale palletizing typical of most SMEs.
It’s also comparatively easier to program than industrial models, so you don’t need a specialized team reprogramming it 24/7.
For operations that need speed and precision on a smaller scale, this SCARA robot delivers performance without the major price tag that typically comes with implementing automation.
But, of course, for bigger operations, you’ll need one of the bigger models on this list.
Absolutely. Case Palletizing robots are designed to work with standard conveyor systems. The robot manufacturer will determine the optimal layout and any necessary modifications to integrate the robot into your current setup. They can also recommend new conveyors if needed.
The space required depends on the robot model and your specific application. In general, you’ll need enough room for the robot to maneuver, grasp, and stack cases, plus space for pallet drop-off and staging. An average robot workcell with two pallet positions will require around 200 to 500 square feet. The robot manufacturer can provide a recommended floor plan for your operation.
The installation and programming process typically takes 4 to 8 weeks. The robot is first installed and tested to ensure all components are functioning properly. Then the robot is programmed for your specific pallet patterns and production requirements. Programming includes teaching the robot the case sizes it will handle, pallet dimensions, stacking patterns, and conveyor positions. The robot is then tested in simulation mode and live production to ensure it meets all your specifications before full operation begins.
The cost of a Case Palletizing robot system ranges from $10,000 to $500,000+ depending on the robot model, number of robots, and any additional equipment or modifications needed. While the initial investment may seem high, many food and beverage companies achieve a return on investment in less than 2 years through increased productivity, reduced labor costs, and improved safety.
Maintenance costs for a robot system are typically $10,000 to $30,000 per year.
That wasn’t so hard, was it? While RO1 takes the top spot for its versatility advanced features, AI, and flexibility, the other options on this list have their own unique strengths – brute force and low cost, respectively
Now, the rest is just finding the right fit for your production environment and budget.