Benefits of Adding a Fully Automatic Robotic Palletizing System - BlueSurf Technologies

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Benefits of Adding a Fully Automatic Robotic Palletizing System to Your Facility

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Benefits of Adding a Fully Automatic Robotic Palletizing System


The industrial automation market is rapidly expanding, with a projected value of $306.2 billion by 2027. The rapid growth is a direct result of the numerous benefits of automation. These advantages grow in tandem with technological advancement. Robotic palletizers are a great example of an automation process that could benefit your company. Continue reading for more information on robotic palletizers and their advantages.


Robotic palletizers are an example of an automated process that could benefit your company in a variety of ways. Typically, automated palletizing is accomplished by using machinery to sort, line up, and turn products as they move down a conveyor belt. They are then stacked on a pallet and wrapped in plastic by turning the entire pallet. Here are some of the advantages of installing a fully automatic robotic palletizing system in your facility.

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The Stack & Wrap mixed layer palletizing packstation is a type of automated palletizing that can be used semi-automatically, increasingly automated, or fully automated.

The pallet itself sits within a mechanism that is lowered to ground level as the pallet is constructed. This means that the top layer of the pallet is always waist-height—ideal, ergonomic positions for workers who build each layer of the pallet by hand.

The Stack & Wrap mixed layer palletizing packstation is a type of automated palletizing that can be used semi-automatically, gradually, or completely.

As the pallet is built, it is placed within a mechanism that lowers it to ground level. This means that the pallet’s top layer is always waist-height—ideal, ergonomic positions for workers who hand-build each layer of the pallet.


As previously stated, this technology can be used in one of three ways:

#1 - Semi-Automated

This is the case described above. While the pallet is automatically wrapped as it is lowered, the pallet is actually built by one or two human operators. Nonetheless, significant advantages are realised, such as increased efficiency and extremely fast throughput rates when compared to a fully manual process. This is accomplished because the system always keeps the top layer of the pallet at an ergonomic height, allowing the worker to perform more efficiently.
Furthermore, by wrapping the pallet as it is built, the system adds strength and stability to the pallet. This allows for the construction of taller pallets without the risk of collapse that would otherwise occur.
The system’s configuration is also very useful for saving space. Because the system has two levels, it takes roughly half the space to palletize and wrap compared to traditional palletization.

#2 - Increasingly-Automated

Finally, by expanding on scenario two, the process can be fully automated. The main difference is that instead of using human operators to build the pallets, you can use one or more robotic arms to receive the cases from the product conveyor and then build the pallet layers without any human intervention. This scenario essentially eliminates the need for any palletizing labour in your operation.

#3 -Fully-Automated

Improved production speeds can be achieved by automating your packing procedure. When a manual packaging method is used, the machine that makes the product is frequently unable to operate at full capacity because the human packaging process cannot keep up with the output. You may therefore remove this constraint and increase your manufacturing speed by automating the packaging of the products.

Benefits of Automated & Semi-Automated Palletizing

Using a palletizing system like the one described above can help your operation realise a variety of benefits, regardless of whether you pursue semi- or full automation. These are some examples:

Design that is modular

A robotic palletizer is much more modular than traditional forms of automated palletizing. Robotic arms are self-contained and can fit into small spaces. Essentially, this means that multiple robotic arms can work on the same or different product lines at the same time. They can also easily switch between programming for various products and pallet plans, allowing for flexibility as needed. This allows warehouses, layouts, and workflows to adapt to changes in the supply chain, business model, and even day-to-day operations.


Robotic palletizers typically provide layer pattern flexibility, such as the ability to overlap bags, tie loads together, and fit larger bags within the confines of a pallet. Robotic palletizers can sort, rotate, and line up products in order to stack them in a specific order. If a pallet needs to be stacked in such a way that all products have the same side facing out, this is simple. This is ideal for food products, for example, in an agricultural engineering setup. If necessary, different products can be stacked on the same pallet. As a result, when considering a robotic palletizer, you have several options.

Expansion and Affordability

Semi-automated robotic arms can help businesses get started with automation while also increasing operational efficiency. These semi-automatic palletizing systems automatically stack pallets while forklift operators remove full pallets. The company can upgrade this system in the future with automated dispensers, slip sheet dispensers, and pallet conveyors to create a fully automated system.

Improved Working Environment

Automated palletizing typically improves the working environment by increasing the safety of your manufacturing process. This process eliminates the manual handling component of palletizing, thereby eliminating the possibility of repetitive strain injuries (RSI) in the workplace. This, in turn, reduces the likelihood of RSI claims occurring and creates a safer working environment for your employees.

Improved Product Handling

When moving and stacking products, eliminate the need for manual labour. They can lift heavier loads and work more quickly. They do not tyre out like humans. If properly maintained, they can even run 24 hours a day, seven days a week. This increases your company’s productivity significantly and eliminates potential bottlenecks in the packaging line.

Increased Productivity

Remove the need for manual labour when moving and stacking products. They can lift heavier loads and work faster. They do not get tired like humans do. They can even run 24 hours a day, seven days a week if properly maintained. This significantly boosts your company’s productivity and eliminates potential bottlenecks in the packaging line.
Our primary goal at Bluesurf Technologies is to increase your productivity and performance. Bluesurf Technologies creates dependable robotics solutions that help you stay competitive and grow. We analyse, programme, integrate, and support robotic systems designed to meet the needs of your business. To learn more about our robotic palletizing systems and to get started, please contact us.


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