Robotic Palletising System

Automating the palletising of products can not only increase throughput but also remove possible injury caused by manual handling. Some processes may only require palletising at the end of line, but one particular customer of SP Automation & Robotics required the system to carry out additional processes, such as product packaging and printing, and reorientation of the product.

The Challenge

The client required a fully automated robotic palletising system that could be integrated into their manufacturing and packaging line. In addition, the customer required the system to carry out additional processes.


  • Maximum cycle time 7 second per package
  • Inkjet marking of packaging
  • Reading and recording of bar code marking
  • Orientation of product to suit pallet layout
  • Automatic feeding of all components
  • Ability to change pallet configuration
  • Two pallet change over

The Solution


The system was based around a series of conveyors that transferred the boxes from the existing carton erecting machine to a position where they were inspected for gross damage and printed with appropriate information.


An ABB IRB660 4-axis robot then collected the box from the end of the conveyor and built them into pre-programmed stack formations on one of two Pallets. Once the first Pallet was filled, the robot automatically moved to fill the second Pallet allowing the operator to manually remove the filled Pallet for shipping and replace the location with an empty Pallet.


Each Pallet location was protected within a fixed guard structure with access provided via a pair of independently interlocked guard doors. Each guard door was fitted with a Castell type interlocks and light curtains to ensure the safety of the operator whilst changing pallets.

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