You do not need to rip out conveyors or pause production to introduce automation. The smarter move is to retrofit compact cobot cells beside your existing lines, keeping end of line processes running while accuracy and throughput climb.
A simple story from a crowded facility
The production line was boxed in by older systems and older buildings. Operators pushed through repetitive tasks at the end of line, swapping patterns on the fly and nursing loaded pallets onto trailers. There was no appetite for greenfield projects, no spare floor, and minimal disruption was non negotiable.
On Friday, we chalked a small footprint for a palletising cell next to the outfeed. Power and safety were pre installed. Over the weekend, a pre assembled Olympus cobot cell rolled in and integrated with the existing system and equipment. Monday, it started lifting boxes and trays, aligned to the conveyor, and placed every case with improved accuracy. The first truck left with neat, secure pallets. No rework, no drama. That short shift changed how the team thought about retrofit projects.
Why retrofit beats rebuild
Retrofit lets companies upgrade the line they already trust. You add a compact, reliable machine that automates routine tasks, reduces operational costs, and frees people for higher value tasks like quality checks and flow. It fits older buildings and existing production lines, even in tight city sites, and avoids the cost and risk of full rebuilds.
- Small footprint that slips beside your conveyor
- Installed fast with a phased plan to cut downtime
- Cost effective compared to large greenfield projects
- Flexible patterns for mixed SKUs, case packing, and trays
What actually changes on day one
Before: end of line packaging processes feel brittle. Patterns drift, speeds vary, and mistakes escalate into disputes.
After: the system locks a stable routine. Heaviest cases stay low and centred, tall items move inboard, slip sheets are prompted when trays meet cartons, and labels face out. Sensors confirm positions. Data logs each run. Loaded pallets travel clean and pass retailer checks.
Built to integrate, not interrupt
These cells are designed to integrate with existing lines. PLC handshakes, safety interlocks, and vision options connect to your existing equipment. The integration is simple. Your team selects a template, the cobot runs it the same way every time, and your operations keep moving.
- Drag and drop setup, no robot programming
- Multi SKU palletising and depalletising in one cell
- Throughput up to 14 cycles or 70 boxes per minute with products up to 23 kg
- Compatible with UK pallets and common conveyor heights
The business case in plain terms
You invest once, then run more efficiently every shift. Automation reduces labour strain, error rates, and chargebacks. Productivity steadies, overtime falls, and operational costs track down. Many retrofit end of line projects pay back in roughly 18 months, faster where mixed case and late trucks are common.
There is a sustainability upside too. Keeping your existing building and equipment reduces environmental impact, while right sized motions, film optimisation, and fewer damaged goods cut waste.
A quick example
A regional manufacturer with a tight end of line could not spare a long shutdown. We installed a compact palletising cell beside the conveyor, integrated to the existing system, and set two patterns. In four weeks, throughput rose, rework fell, and audits passed cleanly. The team shifted focus to higher value tasks, and the business chose to scale the same version to a second line.
How to start without slowing the line
- Walk the line and mark a small footprint where a cell can reach the handover point.
- Pre install power, safety, and network.
- Land the pre assembled cell and connect to your PLC.
- Run a single SKU first, then add mixed SKUs once operators are comfortable.
This phased approach keeps downtime short and confidence high.
What you gain with Olympus
- Compact cobot palletisers built for existing production lines
- Fast installation, commissioning, and UK based support
- Flexible tooling for boxes, trays, and display packs
- Clear data for traceability, alerts, and continuous improvement
You optimise packaging efficiently, protect people and product, and future proof operations with new technologies that respect the constraints of older systems.
Ready to retrofit your end of line
If you want to automate end of line processes without tearing up the floor, retrofit compact cobot cells are the practical path. You keep your facility, your flow, and your customers, and you gain a reliable system that helps your manufacturing community achieve more with less.
Phone: 01484 514513
Email: [email protected]
West Yorkshire, UK. Serving UK and Ireland
