Selecting the correct palletising robot for your manufacturing facility directly impacts your return on investment and operational efficiency.
We consistently find that a tailored approach, rather than a one-size-fits-all approach at Olympus Technologies is to select the right automation solution for your needs.
Palletising with a collaborative robot transforms a bottleneck task into a streamlined, consistent process, freeing human operators for more value-added work.
Our experience at Olympus Technologies shows that a well-chosen cobot can manage 8-15 cycles per minute, depending on the specific product and pallet pattern.
Prerequisites
Before evaluating specific robot models, a clear understanding of your current palletising operation is essential. We first assess the product: its weight, dimensions, and stability.
A single 12.5 kg box, for instance, dictates a different robot choice than four 3 kg bags stacked simultaneously. Then we factor in the desired throughput, identifying your current manual palletising rate and the target cycle time.
For 5 applications, a cobot palletiser needs to achieve 4-8 seconds per pick-place cycle to meet production demands. Finally, we establish the available floor space; often, a cobot's compact 0.19 m² footprint for a UR10e or 0.25 m² for a UR20 offers flexibility even in tight areas.
Steps
Our process for selecting your palletising robot breaks down into three key stages:
1. Payload and Reach Analysis: This is the foundational step. The robot must handle the maximum weight of your product plus the end-of-arm tooling (EOAT). A UR10e handles 12.5 kg, while a UR20 manages 20 kg and the UR30 an impressive 30 kg payload. Just as critical is reach: the robot must comfortably access the conveyor, the pallet, and any slip-sheet or interlayer dispenser without overstretching. The UR20's 1750 mm reach makes it suitable for larger pallets or multiple pallet stations, while the UR30 excels in higher stack heights with its 1300 mm reach. Ignoring either payload or reach leads to either underperforming or oversized installations.
2. End-of-Arm Tooling (EOAT) Selection: The gripper connects the robot to your product. For boxes, we often use pneumatic or vacuum grippers like the OnRobot VGC10, which handles up to 15 kg, or a custom-designed vacuum array for irregular or porous surfaces. Bags require softer, form-fitting grippers. For multiple smaller items, bespoke gripping solutions integrate vacuum cups with mechanical clamps to ensure a secure, consistent hold. We custom-engineer gripping solutions to suit unique product geometries and weights, ensuring reliable handling that speeds up cycle times and minimises product damage. This typically adds £3,000–£15,000 to a project, depending on its complexity but is critical for long-term reliability.
3. Safety and Integration Planning: Collaborative robots significantly reduce traditional guarding requirements, but a thorough risk assessment remains paramount. We ensure the entire cell complies with ISO 10218-1 and ISO/TS 15066 safety standards. This includes evaluating pinch points, collision zones, and integrating safety features such as interlocks on cell access points or light curtains. Furthermore, the robot needs to communicate with existing conveyors, pallet dispensers, and your Production Control System (PCS). Integrating specific URCaps, such as the Robotiq Palletizing URCap, simplifies pattern programming down to under 30 minutes, drastically reducing setup times and allowing operators to manage changeovers without complex programming knowledge.
Validation
After selecting the robot and tooling, we validate the complete solution through detailed simulations and Proof of Concept (PoC) testing in our facility. This allows us to confirm cycle times, ensuring the proposed setup achieves the projected throughput. A typical cobot palletising system delivers an ROI period of 12-18 months for most UK manufacturers, making validation against performance metrics critical from the outset. We simulate 3 pallet patterns and product types to identify potential issues before on-site installation, eliminating costly modifications later. Olympus Technologies' engineering commitment starts with these simulations.
The Variables Most Integrators Overlook
Our experience shows that while payload and reach are primary concerns, overlooking specific operating conditions impacts system longevity and true operational efficiency. The stated specifications for robots like the UR20 assume standard duty cycles under temperate conditions. However, a manufacturing environment operating two or three shifts, especially in ambient temperatures above 25°C, introduces thermal stress on motors and internal components. This directly influences the lifespan of the robot and leads to unpredicted maintenance. We account for these environmental factors through capable system design.
Next, the interaction between the robot and your existing infrastructure presents a critical, yet often underestimated, integration challenge. Effective communication between the cobot, an existing conveyor line, and a pallet wrapper requires more than just a simple I/O connection. Protocol mismatches between legacy PLC systems and modern cobot controllers demand expertise in industrial networking to prevent communication delays or dropped signals, which directly affect uptime. We tackle these challenges by mapping out potential integration pitfalls early in the design phase.
When Payload Ratings Don't Tell the Full Story
The published payload capacity of a cobot is the maximum weight it can lift, static conditions. In palletising, particularly with high speeds or off-centre loads, fluctuating forces come into play. A robot lifts a 12.5 kg box, but if that box is picked with a large, heavy EOAT, or if the acceleration/deceleration profiles are aggressive, the effective load on the robot's joints exceeds its rated payload. This cumulative stress accelerates wear on reducers and bearings, leading to premature failure if not adequately managed during programming and cell design.
The Importance of Pallet Pattern Optimisation
Your pallet pattern is not just about stacking boxes; it’s about stability, transport efficiency, and robot cycle time. A poorly optimised pattern forces the robot into awkward movements, increasing cycle duration and energy consumption. Furthermore, unstable stacks lead to product damage during transport. Working with your logistics team, we design patterns that maximise pallet fill, ensure stack integrity, and reduce the robot's travel distance, optimising both the process and the final product delivery. This detail often determines whether a system hits its 12-18 month ROI target or misses it.
Troubleshooting Common Palletising Issues
Even with careful planning, operational challenges emerge. If your robot palletiser is experiencing inconsistent cycle times, we typically investigate the gripper first. Partial vacuum seals or worn gripper pads on a Schmalz Vacuum Gripper reduce its effectiveness, leading to dropped products or multiple pick attempts. This adds seconds to each cycle. We find routine maintenance for EOAT systems often resolves these issues quickly.
Another common problem arises with product variations. If box dimensions or weights fluctuate outside the programmed tolerances, the robot misplaces items, requiring operator intervention. Our solutions integrate a vision system, such as Pickit 3D, for real-time product verification. This allows the cobot to adapt to minor variations, reject non-conforming items, or adjust its pick-and-place strategy, maintaining continuous operation.
UR Cobot Palletising Solutions
Palletising with a Universal Robot cobot offers flexibility and speed for rapid deployment. We frequently deploy the UR10e for lighter, faster applications, and the UR20 or UR30 for heavier cases or higher stacks due to their increased payload and reach.
| Attribute | UR10e PALLETISING | UR20 PALLETISING | UR30 PALLETISING |
| Payload Capacity | 12.5 kg | 20 kg | 30 kg |
| Reach | 1300 mm | 1750 mm | 1300 mm |
| Footprint | 0.19 m² | 0.25 m² | 0.25 m² |
| Typical Cycle Time | 5-8 seconds per pick | 4-7 seconds per pick | 4-6 seconds per pick |
| Price (Arm only) | £25,000–£35,000 | £35,000–£45,000 | £40,000–£50,000 |
| ROI Period | 12-18 months | 12-18 months | 12-18 months |
| Integration Complexity | Medium | Medium | Medium |
| Target Pallet Height | Up to 1.8m | Up to 2.2m | Up to 2.2m |
| Typical EOAT | Vacuum, lighter clamp grippers | Vacuum, heavy clamp/bag grippers | Heavy vacuum, custom grippers |
Source: Universal Robots official spec sheets / Olympus Technologies typical project data.
Related Guides
Interested in optimising other parts of your production line? Explore our comprehensive range of cobot automation solutions.
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We help UK manufacturers implement strong automation solutions. To discuss your specific palletising requirements or to request a detailed quote, contact our team today. You can also book a free consultation to see how a cobot transforms your operations.
