Total moving mass
Product or multi-pick group, tooling, brackets, valves and services are combined in the payload calculation.
High-payload robotic palletising
Heavy-duty palletising systems for large and demanding loads.
Automate heavy bags, large boxes, bottle packs and multi-pick loads with a long-reach cell engineered for the complete moving payload and your production duty.
80 kgFour-axis reference platform
160 kgHeavy-duty reference platform
3,100 mmPublished reach of 160 kg platform
Application-ledFinal platform and cell confirmed
Application engineering
Heavy products need control as well as capacity.
A high payload figure does not prove a robot can palletise a particular product. The end effector, load offset, acceleration, wrist moments, approach path and required duty must all remain within the selected platform’s limits.
We model the complete moving assembly and proposed cell geometry, then coordinate product and pallet handling around the robot.
Load offset and inertia
Large or eccentric loads can create limiting moments even when their mass is below the headline payload.
Work envelope
Pick position, two or more pallets, top layer, slip sheets and clear approach angles define usable reach.
Structure and floor
Robot base, pallet stops, guarding and high dynamic loads require a suitable mechanical installation.
Complete cell design
Reference platforms up to 160 kg for palletising tasks.
Oxford Industrial Automation lists an 80 kg four-axis palletising reference platform with 2,400 mm reach and a 160 kg multifunctional palletising reference platform with 3,100 mm reach. These are starting points for application assessment, not a complete cell specification.
Final selection is confirmed only after the product, end effector, paths, cycle, environment, safeguarding and surrounding equipment have been reviewed.
- Robot load case checked through the full motion path
- Gripper structure and services included in payload
- Multi-pick quantity balanced against rate and inertia
- Base, floor and mechanical interfaces reviewed
- Product and pallet zones arranged for clear, controlled access
What we need to know
Size the cell from the worst credible load case.
The heaviest product is not always the limiting case. A lighter, larger or more eccentric pack can create a more demanding moment at the robot wrist.
| Design input | Why it matters | What to provide |
|---|---|---|
| Load cases | Different SKUs and multi-pick groups create different mass, centre-of-gravity and inertia conditions. | Dimensions, mass, centre of mass if known and pick quantity for every SKU. |
| Tool concept | Tool weight and load offset can consume substantial robot capacity. | Preferred contact areas, prohibited surfaces and required functions. |
| Work envelope | Long reach at the highest layer or far pallet may be the limiting position. | Dimensioned layout, pallet positions, heights and access constraints. |
| Cycle and duty | Acceleration, dwell, multi-line demand and shift pattern affect performance and thermal duty. | Products/min, pick grouping, shifts and expected availability. |
| Installation | Base loads, floor quality and traffic separation affect mechanical and safety design. | Floor information, site photos, services and forklift routes. |
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
High-payload engineering across the complete cell.
The robot, end effector, base, conveyors, pallet fixtures and safeguarding are treated as one machine with defined load cases and interfaces.
Engineered end effector
Structural frame, gripping method, compliance, sensors and service routing designed for the real product and worst-case motion.
Mechanical installation
Robot base, floor interfaces, guarding posts, pallet location and conveyor structure coordinated around dynamic loads and access.
Cell control
Product demand, multi-line arbitration, pallet status, recovery and safe access managed through PLC, HMI and safety control.
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
Heavy-duty palletising questions.
What makes a palletising system heavy-duty?
It may involve heavy individual products, several products per pick, a large or offset end effector, long reach, high stack height, multi-line demand or sustained duty. The full load case and work envelope define the requirement.
Is a 160 kg robot suitable for a 160 kg product?
Not necessarily. The stated robot payload must also carry the end effector, brackets, hoses and other moving components, and allowable wrist moments and inertia must be respected. A 160 kg product would therefore normally need a higher-capacity platform.
Can one heavy-duty robot palletise two lines?
Potentially. A multi-line layout requires a cycle-time and reach study, product-buffer strategy and rules for prioritising demand from each line.
Can heavy bags and boxes run on the same cell?
Possibly, but the gripping requirements may be very different. A common tool, controlled change parts or automatic tool changing can be assessed against rate, payload and complexity.
Do you check the floor and robot base?
The installation requirements form part of the cell engineering. Final base and floor suitability must be confirmed against the selected robot, dynamic loads and site conditions.
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