Automated Palletising Systems: A Practical Guide for UK Manufacturers

If you’re weighing up how to boost throughput, reduce manual handling, and keep pallet loads consistent, Automated Palletising Systems are often the fastest route to measurable improvements. They remove the variability that comes with repetitive manual stacking, protect staff from strain-heavy tasks, and create cleaner, more predictable end-of-line performance. At Premier Automation, we design and build new robot cells, integrate used robots, and upgrade or relocate existing automation so you get the right solution for your product, your site, and your payback targets.

Modern palletising is not “one size fits all”. The best-performing cells are designed around your pack format, line speed, available footprint, pallet patterns, and what happens before and after pallet build (labelling, checkweighing, stretch wrapping, and dispatch). The goal is a robust system that runs smoothly day to day, not just a cell that looks good on paper.

Automated Palletising Systems: What They Are and Where They Fit

Palletising automation sits at the end of a production or packing line, stacking cases, trays, sacks, or other packaged goods onto pallets in stable, repeatable patterns. A well-designed cell is about more than the robot. It needs controlled product presentation, reliable gripping, safe guarding, and a control system that operators can use confidently.

In practice, palletising is most valuable when you want to:

• Increase output without continually adding labour
• Improve pallet quality for storage and transport
• Reduce product damage from inconsistent stacking
• Reduce manual handling risk and fatigue
• Create capacity for unmanned or low-manned running

Because every factory is different, Premier Automation applies process and design expertise to confirm whether palletising is the right fit, and if so, what level of automation is appropriate.

Automated Palletising Systems: Key Components of a Robust Cell

Reliable palletising performance comes from getting the fundamentals right. The main building blocks typically include:

Product infeed and presentation
Conveyors, guides, and (where needed) pre-orientation keep product consistent as it enters the robot pick zone. This is a common difference between “good” and “great” performance, especially at higher rates.

Robot and end-of-arm tooling
Robot selection depends on reach, payload, speed, and duty cycle. Tooling is equally critical: a gripper must suit your packaging, tolerate variation, and maintain grip reliability over time. Premier Automation has designed special grippers for many different products, and we tailor solutions for single and multiple lines.

Pallet management
Many cells include an empty pallet stack with automatic pallet picking, plus sensors and routines to manage pallet presence, layer height, and pattern changeovers.

Peripheral integration
Depending on your operation, the cell can be integrated with stretch wrappers, pallet conveyors, weigh scales, printers, or warehouse interfaces. Integration is often where downtime is won or lost, so it should be engineered as one coherent system.

Controls and safety
The control system is the heart of the cell. Premier Automation designs control systems in Eplan and delivers full documentation, including parts lists, panel layouts, cable schedules, safety reports and controls risk assessments. Operator interfaces should be intuitive, with clear status, alarms, and guided recovery steps to minimise stoppages.

Automated Palletising Systems: Selecting the Right Approach

The “right” cell is the one that matches your technical needs and commercial targets. Typical options include:

Single position palletising cells
Ideal for one line feeding one pallet location. This is often the simplest route to automation with a strong payback.

Twin position palletising cells
Two pallet positions allow pallet exchange without stopping the line. This is a proven way to maintain continuous flow and handle different products or pallet patterns.

Multi-infeed solutions
When you have multiple packing lines, a single robot can sometimes service more than one infeed, depending on rates and pick complexity. This can reduce capital spend while still delivering major benefits.

Cobot palletising
Cobots can be attractive where rates are moderate, space is tight, or you want easier redeployment. They also suit high-mix operations where quick reconfiguration matters. However, the decision should be based on cycle time, payload, and duty cycle, not just footprint.

A practical selection method is to define your “must-haves” first: product sizes, line rate, available space, pallet patterns, shift coverage, and future range changes. From there, cell design and simulation can be used to validate performance before build.

Integration, upgrades and relocation for existing systems

Not every project starts with a clean sheet. Many manufacturers already have robots on site that can be re-engineered to work more efficiently, reduce cycle times, or cope with new products. Premier Automation regularly upgrades legacy automation by improving tooling, refining product presentation, modernising controls, and updating programming to reduce downtime.

Where appropriate, we can integrate used robots into new or existing cells to meet process requirements and payback criteria. We also relocate automation locally, nationally, or internationally, managing the practicalities of dismantling, transport, installation, recommissioning, and training.

Payback, uptime and what “good” looks like on the shop floor

A palletising cell should deliver value in measurable ways: throughput, labour reduction, fewer handling incidents, lower damage rates, and stable pallet quality. Automated Palletising Systems also support better planning because they create predictable end-of-line behaviour and reduce last-minute disruption.

To protect uptime, focus on:

• Maintainable tooling with easy access to wear parts
• Clear fault recovery routines on the HMI
• Offline programming where possible to minimise production disruption
• Strong documentation and training so operators are confident

Premier Automation’s software engineers use offline tools to develop and edit programmes to reduce disruption at installation, and our team supports commissioning and training so the system becomes a dependable part of daily production.

Frequently asked questions

How long does a palletising project take?
Timescales vary by complexity, but a standard cell is typically quicker than a bespoke multi-line system. The most important factor is agreeing scope early, including product range and downstream integration.

Can you integrate palletising with a stretch wrapper?
Yes. Many installations are integrated with downstream equipment so pallets can be wrapped and conveyed without manual intervention.

Do you only work with one robot brand?
No. Premier Automation has experience integrating a wide range of robot models from leading manufacturers, and we match the platform to the application.

What if our product changes next year?
Designing for change is part of good automation. Tooling, infeed design, and software structure can be built to accommodate future formats, new pallet patterns, or throughput changes.

Talk to Premier Automation about your palletising requirements

If you want a reliable end-of-line solution that meets your technical brief and commercial targets, Premier Automation can help you specify, design, build, upgrade, or relocate a palletising cell that fits your site. Automated Palletising Systems work best when they are engineered around real production constraints, with honest advice on what will and won’t deliver the outcome you need.