Labour gaps, more SKUs, and tighter quality targets are squeezing teams.
Cobot case packing removes repetitive, accuracy-critical work and lifts productivity without rebuilding the whole line.
It fits into existing buildings, uses small cells, and helps you reduce costs while improving results.
For layouts and real-world options, explore Case Packing Solutions.
What Cobot Case Packing Means
A cobot case packer is machinery that uses a collaborative robot to pick, orient, and place items into cases.
Safety features allow people to work nearby. Compared with hard-guarded systems, you create recipes, run compact cells in tight space, and change formats quickly.
Typical cases include top-load, side-load, mixed SKUs, and fragile products that need a careful form and gentle handling.
When the cases reach the end of the line, a natural next step is Cobot Palletising.
Where Cobots Fit In Existing Buildings
Most projects must work inside the building you already have. Cobots make that easy.
- Layout. U-shaped or corner cells fit beside conveyors, even through standard doors. Mobile bases let one unit support two lines.
- Services. Confirm power, air, network, floor loading, and earthing. Keep maps, drawings, and files in one place so architects, engineers, and the operations community stay on the same song sheet.
- Flow. Stabilise infeed, add a case erector and taper, then hand off to palletising with a short, direct run.
If you need upstream adhesive control, see Dispensing and Sealing.
Why Cobots: The Business Case
- Faster changeovers for short runs and high SKU variety
- Higher pick accuracy and consistent quality
- Small footprint that protects space in busy aisles
- Collaborative operation with minimal guarding and clear sign points
- Lower investment and total cost of ownership with quicker payback
Core Building Blocks You Will Need
Hardware. Select a UR robot with the reach and payload to match case size, tool mass, and pick distance. Choose grippers based on surface and porosity, for example vacuum, finger, or hybrid. Add vision cameras, slip-sheet options, and compact guarding or scanners after a risk assessment.
Software. Create and save pack patterns as recipe files, then select by SKU or job. Set vision calibration once, capture barcode and batch data automatically, and enable WMS or ERP triggers. Error handling should flag the wrong conditions early so operators can pause, accept, reply, and continue safely.
Integration. Upstream, manage accumulation, orientation, and label checks. Downstream, merge and buffer before palletising. Keep HMI settings simple, log by line, day, and time, and base improvement on relevant data rather than guesswork.
Implementation: Start, Build, Enhance
- Survey and plan. Set throughput targets, build the SKU matrix, measure case sizes, and draft a scaled floor plan showing lines, doors, and access. Decisions are stronger when they are based on real constraints.
- Build and commission. Install mechanics, map I/O, load recipes, and validate with FAT and SAT. Keep CE and UKCA documentation, earthing checks, and safety test records with the machine files.
- Train and optimise. Train operators on safe start-up and recovery. Tune grip forces and robot paths, then release a clean recipe set. Use PDCA to reduce cycle time and enhance first-pass yield. What works on one cell can scale across sites.
Performance, Costs, And ROI
Track picks per minute, cases per minute, first-pass yield, downtime, and OEE. Look at results by shift to find the best way to improve.
Quick wins often come from better vacuum settings, tidier case presentation, and shorter paths. Decisions on investment should be based on captured data. As new SKUs are created or released, recipes can be added automatically to keep the pace up today and in the future.
Safety And Compliance Essentials
Complete a documented risk assessment to Performance Level d or e where required. Choose scanners or light curtains to suit approach speeds, validate safe robot speeds, and sign off lockout procedures and training. Earth bonding, tidy cable routing, clear sign locations, and start-of-day checks reduce downtime and keep people safe.
Limits And Practical Workarounds
- Very high speeds. Use dual-pick tools, multi-head designs, or a hybrid cell paired with a compact case packer
- Irregular or porous packs. Apply adaptive vacuum, custom tooling, and robust vision
- Tight space. Use vertical lifts, corner cells, and shared bases to keep aisles clear
Cobot Case Packing vs Traditional Machinery
| Technology | Typical speed | Footprint | Changeover time | Flexibility | Capex | Best for |
|---|---|---|---|---|---|---|
| Cobot case packing | 2 to 20 cases per min | Small to very small | Minutes via recipes | High, mixed SKUs and fragile | Lower to mid | Brownfield lines, quick format change |
| Traditional case packer | 15 to 60 plus | Medium to large | Longer, mechanical | Lower once set | Mid to higher | Long runs of stable SKUs and formats |
Quick Spec Checklist
- Throughput in cases per minute, shift pattern, SKU count
- Case dimensions and weights, product stability, pack pattern and form
- Infeed and outfeed height, available footprint, guarding preference
- Data needs for WMS or ERP, labelling, QA checks, and file retention
FAQs
Can cobots handle mixed-SKU cases?
Yes. Recipes, barcode checks, and vision make mixed cases practical while keeping traceability intact.
What training do operators need?
Start with safe start-up, recipe selection, and simple recovery. Technicians handle gripper setup, vision calibration, and recipe control.
How fast is a changeover?
Usually minutes. Select the recipe, add a quick tool swap if needed, confirm alignment, and run a short test.
How do cobots work with my WMS?
Through straightforward data exchange. Barcode triggers start jobs, results post back automatically, and batches are recorded by time and line.
