Case integrity
Corrugated grade, closure, compression strength, bulging and open flaps determine where the pack can be supported.
Robotic case and carton palletising
Robotic box palletising systems for cases, cartons and trays.
Reduce repetitive manual stacking and build consistent pallets with a complete cell designed around your case sizes, output, pallet patterns and changeovers.
CasesTaped, glued or open-top formats
Multi-SKURecipe-led production changeovers
1 or morePallet positions assessed by layout
CompleteConveyors, tooling, controls and safety
Application engineering
A stable pallet begins before the first case is picked.
Box palletising is not simply a robot moving a rectangular object. Case quality, centre of mass, conveyor gaps, label orientation and the way a pack arrives at the pick position all affect repeatability.
We review the complete end-of-line process so the cell can square, stop, detect and pick each case consistently before building the specified layer pattern.
Product presentation
Infeed direction, spacing, orientation and accumulation strategy establish a reliable robot pick condition.
Pattern stability
Interlocked or column-stacked layers, overhang, gaps and label-facing rules are defined for the actual case sizes.
Rate and changeover
Cases per minute, SKU sequence, batch size and pallet exchange time are considered together—not in isolation.
Complete cell design
End effectors matched to the carton and duty.
Vacuum tooling is often effective for sealed cases with a consistent, non-porous pick face. Fork, clamp or combined tooling may be more suitable where surfaces leak, packs distort or multiple cases need to be handled together.
The gripper is engineered with sensing and fault handling so a missed or unstable pick is detected before it compromises the stack.
- Single-case, row or multi-case pick strategies
- Vacuum zoning and product-present confirmation
- Case squaring, turning and controlled accumulation
- Automatic or manual pallet presentation
- Slip-sheet, tier-sheet and layer-pad options where required
What we need to know
The details that define a box palletiser.
A short product and line data set lets us assess likely architecture, payload, reach and peripheral equipment before detailed engineering.
| Design input | Why it matters | What to provide |
|---|---|---|
| Case range | Affects gripping area, change parts, robot path and pattern feasibility. | Minimum and maximum L × W × H, mass and photographs. |
| Pack construction | Porosity, tape seams, top load and bulging influence the gripping method. | Board grade if known, closure style and sample cases. |
| Production rate | Sets the available cycle time including robot travel and pallet exchange. | Cases/min by SKU, bursts, planned stops and shift pattern. |
| Pallet specification | Determines reach, stack height, clearances and outfeed handling. | Pallet L × W × H, maximum loaded height and load mass. |
| Pattern rules | Defines layer geometry, orientation, gaps and label-facing requirements. | Current pattern drawings or a representative finished pallet. |
Payload is more than product weight. Robot selection must include the product, gripper, brackets, hoses, valves and any multi-pick tooling in the complete moving payload.
Integrated around the robot
A complete case palletising cell, not an isolated arm.
The surrounding equipment creates the repeatable pick, manages empty and full pallets and gives operators a controlled route for changeover and recovery.
Product infeed
Conveyors, stops, turners, squaring devices, accumulation and product detection configured around the upstream machine.
Pallet handling
Empty-pallet presentation, pallet dispensers, centring, full-pallet outfeed and interfaces to forklifts or conveyors.
Controls and safety
PLC and HMI control, recipe selection, guarded access, interlocks, emergency stops and defined recovery sequences.
Project route
From production brief to handover.
A palletising project is only complete when the robot, product flow, pallet handling, control system and operator access work together. We keep the system boundary clear from the first layout.
See complete cell integrationDefine
Products, rates, patterns, pallet formats, line interfaces and site constraints.
Engineer
Robot, end effector, conveyors, safety architecture, controls and cell layout.
Prove
Programming, dry testing, product trials, recipe checks and agreed acceptance evidence.
Deploy
Installation, commissioning, operator training and production handover.
Frequently asked questions
Box palletising questions, answered.
Can one robot palletise several case sizes?
Often yes. The feasible range depends on case dimensions, mass, gripping surface, pattern and cycle time. A recipe-based cell can change robot paths and patterns, while the end effector may be fixed, adjustable or fitted with controlled zones.
Can labels or barcodes face outwards on the pallet?
Yes, where the infeed presentation and pattern allow it. Product turning, robot orientation and recipe rules can be designed to maintain a specified label-facing direction.
Can the system serve two pallet positions?
A robot can often build on two pallet positions or serve multiple infeed lanes, but reach, cycle time, guarding and pallet exchange must be checked on the proposed layout.
What happens when a case is missing or misaligned?
The cell can use product-present, position, vacuum and other sensors to stop or recover in a controlled way. The required detection and recovery strategy is agreed during engineering.
Do you integrate pallet dispensers and conveyors?
Yes. Empty-pallet dispensing, pallet centring, full-pallet conveyor outfeed and surrounding line interfaces can be included within the complete system scope.
Related systems
Explore the wider palletising cell.
How are open-top boxes palletised without crushing or spilling the product?
Open-top boxes need a grip and motion strategy that supports the pack without relying on an unsuitable open surface. Side clamps, forks or another proven tool may be considered with controlled acceleration, case presentation and layer design. Representative filled cases must be trialled.