Stacking cartons, cases or bags onto pallets is heavy, repetitive work. In many factories, it is still done by hand, causing fatigue, injuries and inconsistent pallets. Automatic palletisers solve these problems. The two main choices are robotic palletisers and conventional layer-forming palletisers. Each has strengths that suit different operations.
Conventional Palletisers
Conventional palletisers form a complete layer of cases using conveyors, turning devices and pushers, then transfer the layer onto the pallet. They come in high-level and low-level designs.
Strengths:
- Very high speeds for single product lines
- Proven technology for large volumes
- Neat, consistent pallet patterns
Considerations:
- Larger footprint
- Less flexible for frequent product changes
- More mechanical complexity
Robotic Palletisers
Robotic palletisers use an industrial robot arm with a gripper to pick cases or bags and place them on pallets.
Strengths:
- Flexible: new products and patterns can be programmed
- Can handle multiple lines and pallets simultaneously
- Compact footprint
- Handles cases, bags, crates and other items with different grippers
Considerations:
- Speed is limited per robot, though layer grippers increase output
- Requires programming skills
- Safety guarding and space for robot movement
Comparing Flexibility
If your factory produces many SKUs with different case sizes and pallet patterns, robotic palletisers adapt easily. Conventional palletisers are best for long runs of the same product.
Comparing Speed
Conventional palletisers achieve very high speeds suitable for large beverage plants. Robotic palletisers suit low to medium speeds, though advanced systems can reach higher outputs.
Space and Layout
Robotic cells are compact and can serve several lines. Conventional palletisers need more space and dedicated conveyors.
Safety
Both types require safety guarding. Robotic cells use fencing, light curtains and safety controls. Proper risk assessment is essential.
Cost
Costs vary widely. Robotic palletisers have become more affordable and are increasingly popular with small and medium manufacturers.
Grippers Make the Difference
On a robotic palletiser, the gripper is just as important as the robot. Vacuum grippers handle cartons with sealed tops. Fork or clamp grippers handle bags and heavy cases. Layer grippers pick a whole layer at a time, increasing speed significantly. Some grippers can also pick slip sheets and empty pallets, allowing one robot to build an entire pallet without manual help. When evaluating robotic systems, ask to see the gripper handling your actual cases or bags, especially if they are soft, heavy or irregular.
Pallet Patterns and Stability
Both palletiser types can create interlocking patterns that tie layers together and improve stability. The best pattern depends on case size and pallet dimensions. A good palletiser supplier will propose patterns that maximise pallet use while keeping the load stable.
Integration With the Rest of the Line
Palletisers sit at the end of the line, after case packers and before stretch wrappers. Conveyors with accumulation between these machines help keep the line running if one machine stops briefly. Planning the full end of line together, rather than adding machines one by one, avoids bottlenecks and wasted space.
Choosing the Right Palletiser
Consider your speed, product range, space, budget and future plans. If flexibility matters most, robotic is usually the answer. For very high speeds with stable products, conventional palletisers remain strong.
Hilden supplies end-of-line automation solutions and can help you evaluate palletising options that match your production needs.
