Palletising Robot Systems: A Practical Guide to Faster End-of-Line Automation

Palletising Robot Systems are one of the most proven ways to improve end-of-line performance in manufacturing and logistics. If your operation relies on manual stacking, you will be familiar with the issues: fatigue, inconsistent pallet quality, manual handling risk, and the challenge of keeping up with peak demand. A well-designed robotic palletiser delivers consistent cycle times, stable pallet loads, and a safer working environment, while freeing operators to focus on higher-value tasks.

At Premier Automation, we design and build new robot systems, integrate used robots, and modify or update existing automated systems to meet customer process requirements and payback criteria. Founded in 2000, we have developed into one of the UK’s leading suppliers of robot-based automation and control systems, with extensive experience integrating a wide range of robot models across diverse applications. Our approach is honest and unbiased: automation is powerful, but it is not suitable for every scenario, and we will guide you to the most appropriate solution.

This guide explains how palletising systems work, what options exist, and how to specify a solution that is reliable, safe, and straightforward to operate.

Palletising Robot Systems: What’s Included in a Typical Cell

A palletising robot is only one part of a complete solution. The best Palletising Robot Systems are engineered as a cell, where robot motion, infeed flow, pallet patterns, safety, and downstream equipment all work together. The cell is designed around your product type, throughput requirement, and available space.

Most palletising cells include:

• Robot, controller, and a safety-rated control system
• Infeed conveyor(s) and product management
• End-of-arm tooling (gripper) designed for your cartons, bags, trays, or cases
• Pallet station(s), including pallet magazines or pallet stack handling if needed
• Machine guarding, interlocks, and emergency stop circuits
• HMI interface for operators, alarms, and production status

Premier Automation has designed special grippers for many different products and built systems for single and multiple lines. Where required, we integrate palletising with other equipment such as stretch wrappers to create a complete end-of-line solution.

Palletising Robot Systems: Throughput, Quality and Safety Benefits

The business case for Palletising Robot Systems usually includes a combination of productivity improvement and risk reduction. Robotic palletising brings consistency to a task that is otherwise heavily influenced by fatigue and shift variation.

Common benefits include:

• Higher throughput with predictable cycle times
• Consistent pallet patterns that improve load stability
• Reduced product damage caused by poor placement or rushed manual stacking
• Improved workplace safety by removing repetitive lifting and awkward handling
• Better use of floor space through optimised pallet layouts
• Potential for extended running with reduced supervision

Robotic palletising also supports more reliable downstream operations. Uniform pallets are easier to wrap, store, and transport. That reduces rework and helps avoid issues such as leaning loads, collapsed stacks, or damaged goods in transit.

From a safety perspective, palletising is an ergonomically demanding task. Removing repetitive lifting reduces strain injuries and helps keep your team healthier and more productive in the long term.

Palletising Robot Systems: Choosing Between Industrial Robots and Cobots

Not every application needs the same type of robot. Payload, reach, speed, and available space all influence the most suitable approach. Industrial palletising robots are typically used for higher-speed, heavier-duty applications, while collaborative robots can suit lower payloads and flexible production environments.

Industrial robots can be ideal when you need:

• High cycle rates and consistent high output
• Larger reach across multiple pallet positions
• Heavier payloads or more demanding handling
• Continuous operation with minimal downtime

Cobots can be a good fit when you need:

• Fast changeovers for high-mix, low-volume production
• A compact cell footprint in a constrained area
• Easy reconfiguration of pallet patterns and product handling
• Tasks where collaborative features support flexibility

Premier Automation builds both traditional palletising cells and cobot palletising cells. For example, we have systems based around ABB palletising robots as well as ABB GoFa cobots, with options including single or multiple pallet positions and pallet conveyor configurations. The key is selecting the right platform for your throughput and product range, rather than choosing based on trend.

Palletising Robot Systems: Control Systems and Safety Integration That Last

The control system sits at the heart of Palletising Robot Systems. It governs robot motion, conveyor logic, safety devices, and operator interaction. A good control system should be intuitive for operators, robust for maintenance teams, and compliant with relevant standards.

Premier Automation specialises in designing and manufacturing control systems for robots, special purpose machinery, and process lines. Our designs are produced in the latest Eplan platform and delivered with full schematics, parts lists, panel layouts, cable schedules, EN13849 safety reports, and controls risk assessments. We are proud to be a Siemens Solution Partner, and our control panels are built internally by fully qualified electricians, tested prior to despatch, and compliant with relevant British and European standards and directives.

Safety integration typically includes:

• Guarding or safety-rated scanning depending on the cell
• Interlocked gates and emergency stop circuits
• Clear access arrangements for pallet changes and maintenance
• Risk assessment and validation during commissioning

This approach ensures the palletising cell is safe to operate, simple to understand, and reliable over the long term.

Palletising Robot Systems: Design, Simulation and Programming to Minimise Downtime

Programming and commissioning are critical stages in any robotics project. Poor programming can lead to lost throughput, excess wear, and avoidable faults. Premier Automation provides robot and PLC programming support across a wide range of systems, and we use off-line programming tools such as Robot Studio and Siemens PLC Sim to create and edit programmes without shutting down production.

Off-line programming supports:

• Digital twin development to optimise cell design before build
• Faster commissioning on site with fewer unexpected issues
• Reduced downtime when modifying existing palletising cells
• Safer and more controlled testing of new pallet patterns

On-site robot programming is also available for improving system performance, accommodating new products, or supporting upgrades to existing systems.

Upgrades, Re-Engineering and Relocation

Many manufacturers already have automation, but it may not be performing as it should. A palletiser might have become inefficient, worn, or unsuitable for new products. In those cases, re-engineering can deliver the benefits of modernisation without a full replacement.

Premier Automation supports:

• System assessments and site surveys
• Upgrades to improve cycle time and reliability
• New tooling and grippers designed for new product ranges
• Safety upgrades and control system modernisation
• Relocation within a site, across the UK, or internationally

We also have in-house machining and fabrication capabilities for components such as pedestals, support frames, guarding, and spreader plates, helping reduce lead times and keep projects cost effective.

Making the Right Investment in End-of-Line Automation

Palletising Robot Systems deliver the best results when they are designed around your products, your space, and your commercial goals. The right system improves safety, increases output, reduces damage, and creates a reliable end-of-line process that supports the rest of your operation.

Premier Automation welcomes the opportunity to review your palletising requirements, share our experience, and guide you to the most appropriate solution, whether you need a new cell, a cobot palletiser, or an upgrade to an existing system.