When it comes to the end of line, palletising might not sound glamorous - but it’s one of the most critical parts of any production process.
Traditionally done by hand, stacking boxes onto pallets is repetitive, physically demanding, and not exactly a dream job for your team. But the game is changing, thanks to clever palletising software for cobots.
In this guide, we’re diving into how cobots (collaborative robots) are revolutionising the way we automate palletising tasks.
With the right software, even small manufacturers can boost productivity, reduce injuries, and increase operational efficiency - all without breaking the bank or halting production.
Let’s unpack it.
Why Automating Palletising Just Makes Sense
Manually stacking pallets might get the job done, but it comes at a cost: inconsistent quality, production downtime, and a high risk of workplace injuries. Enter the cobot - a flexible robotic arm that’s designed to work safely alongside people and take over those repetitive tasks.
What really makes the difference, though, is the palletising software. It gives the cobot the smarts to build custom pallet patterns, handle variable box sizes, and adjust to different pallet heights or weights without needing manual reprogramming.
In fact, switching to a cobot palletising solution can boost throughput by over 30% in real-world installations. That’s a serious improvement especially if your team’s juggling growing production demands.
The Big Benefits of Cobot Palletising Software
Let’s break down what makes this tech so powerful.
1. Better Throughput, Less Stress
Cobots don’t take coffee breaks. Once programmed, they keep going at a steady, optimised pace. That means your production line stays consistent, even during shift changes or overtime.
Plus, because the system can be set up to pick one or more boxes at a time (a standard pick or multi-pick configuration), it’s capable of building pallets much faster than manual labour.
2. Lower Labour Costs (and Happier Staff)
Let’s be honest - no one signs up for endless lifting and twisting. Automation removes that burden. You need fewer operators for palletising, which means you can assign your team to tasks that actually add value. You save on overtime and reduce turnover, all while maintaining a steady output.
3. Fewer Injuries, Better Morale
Manual palletising is a major contributor to musculoskeletal injuries in manufacturing. By using cobots, you take workers out of harm’s way while creating a healthier, safer workplace. And yes, morale goes up when the robot takes the strain.
4. Precise, Reliable Stacking
With palletising software, every layer is placed exactly where it should be - no crooked stacks or wasted space. That kind of accuracy improves pallet stability, cuts shipping issues, and saves time fixing errors down the line.
Plus, modern systems can be programmed to handle different stacking configurations depending on box size or shipping requirements.
5. A More Predictable Workflow
Integrating a palletising application into your existing workflow reduces bottlenecks and keeps your line moving. Add a dual-pallet setup, and you’ve got a seamless operation: one pallet stacks while the other gets swapped out, with no pause in between.
Industries Where Cobot Palletisers Shine
This tech isn’t just for big factories. From food producers to pharma to consumer goods, a wide range of sectors are turning to automation at the end of line. Here’s where cobot palletisers are making a serious impact:
Food & Beverage
Speed and gentle handling are key here. Whether it’s boxes of crisps or crates of bottled drinks, cobots keep up with fast-moving lines and stack without damaging packaging.
- After installing a cobot palletiser, Bart Ingredients saw a 33% boost in efficiency, reduced labour needs, and eliminated their end-of-line bottleneck.
Pharmaceuticals & Healthcare
Lightweight, high-volume packaging? Cobots are perfect. With precise control, you can automate stacking of boxes containing tablets or medical kits, even in cleanroom environments.
- E&O Laboratories deployed cobots to palletise sleeve-wrapped bio-culture packs with zero damage and 15-pack-per-minute throughput.
Consumer Goods & FMCG
Frequent product changeovers and varied box sizes are common - which is where the versatility of cobot palletising comes into its own. Just update the programming, load a new pattern, and the robot adapts.
Chemicals & Agriculture
Heavy or hazardous items? Cobots reduce risk and handle everything from chemical drums to sacks of animal feed. When configured with the right gripper and safety features, these systems are more than capable of handling demanding tasks safely.
How Cobot Palletising Software Makes It All Possible
The real magic behind cobots is the software. Here’s why it matters:
Intuitive Programming - No Expertise Needed
Today’s palletizing software is built for ease of use. Many systems offer drag-and-drop interfaces, so you can create or change a stacking pattern in minutes. Operators don’t need coding experience - just a basic understanding of the system and a few quick taps on a touchscreen.
Compatibility with Different Robot Arms
Whether you’re using a Universal Robots UR20, a FANUC CRX, or another robotic arm, most palletising software is designed to integrate smoothly. That means your investment is protected - the same configuration and logic can often be reused or adapted across models.
Built-In Safety Features
Cobots are designed to be safe, but the software adds another layer of protection. If someone steps into the palletising zone, the robot can automatically slow down or stop, thanks to built-in sensors and smart control logic.
Easy Integration with Production Lines
These systems connect with your conveyors, line sensors, or PLCs to make decisions in real-time. They can start picking when a box arrives or pause when a pallet is full - all without manual input. The result? Seamless operation from box to warehouse.
What to Look for in a Cobot Palletising Solution
Not all systems are created equal. If you’re exploring options, here’s what you’ll want:
A Compact Footprint
Factory space is precious. A small footprint palletising system - often no bigger than two pallets side by side - fits neatly into existing lines without major layout changes.
High Payload Capacity and Smart Stacking
Choose a cobot that’s capable of handling your heaviest items, and software that can optimise picks per cycle. For example, a UR20-based system can lift boxes up to 23 kg and build out multiple pallets per hour.
Flexibility for Growth
Need to add a second pallet? Want to switch from stacking boxes to handling bags? A modular, scalable system lets you expand as needed - without starting from scratch.
Fast ROI and Low Maintenance
Thanks to lean designs and reduced reliance on manual labour, most cobot palletisers pay for themselves faster than more expensive options. Plus, with fewer moving parts, maintenance is minimal - often just the occasional suction cup replacement or firmware update.
Olympus Technologies Cobot Palletising Solution
The Olympus Technologies UR Palletising System offers the smallest footprint cell whilst enabling the robot to safely palletise at it's maximum cycles per minute.
Features
- No robot programming required
- Offline pallet configuration
- Offers both palletising and de-palletising
- Fully customisable cases and pallets
- Picks single and multiple cases
- Non-stop operation
- Designed-to-fit bespoke gripper(s)
- Mobile solution available
- Footprint - 3.2m x 2.8m
- Up to 11 cycles per minute
- Up to 23kg cases
- Up to 1200mm x 1000mm pallets
- De-palletisating
- Multi-Sku
- Palletising
- Re-Palletising
- Compatible with Interlayer cards
- Fully UKCA and CE Marked Solution
- Full UK Support
Find out more about the Olympus Technologies Palletising System here.
Real-World Wins: Companies That Got It Right
Bart Ingredients - Food Manufacturing
After installing a cobot palletiser, Bart Ingredients saw a 33% boost in efficiency, reduced labour needs, and eliminated their end-of-line bottleneck.
Read the Bart Ingredients case study here.
E&O Laboratories - Pharmaceuticals
A first-time automation project for the UK’s largest privately owned manufacturer of ready-to-use culture media turned out to be a huge success. The cobot palletised sleeve-wrapped bio-culture packs without damaging them with precision and helped maintain quality at scale.
Read the E&O Laboratories case study here.
Getting Started: What Implementation Looks Like
Deploying a palletising solution doesn’t have to be complicated.
- Site assessment helps define your palletising requirements and choose the right robot and gripper
- Installation is usually completed in a few days, with most systems arriving mostly pre-assembled
- Training is fast - most operators can learn the functionality of the Olympus Palletising Software in a matter of hours
- Integration into your existing facility and control systems is smooth, thanks to plug-and-play compatibility
You’re not tearing down your line - you’re enhancing it.
Final Thoughts: Why Now’s the Time to Automate
If you’re still stacking pallets by hand, there’s a smarter way forward. With modern palletising software for cobots, you can automate safely, boost productivity, and meet rising production demands - all with a solution that’s scalable, easy to use, and cost-effective.
The tech is ready. The ROI is proven. And whether your project is big or small, there’s a cobot palletiser system that fits your space, your workflow, and your goals.
The future of end-of-line automation isn’t coming - it’s already here.
