EN
Robotic Palletizer
This fully automatic robotic palletizing system is equipped with original KUKA industrial robot, customized clamp gripper, automatic pallet feeding & discharging conveyor, box separating & layer grouping station, and safety perimeter protection. Designed for automatic palletizing of film-wrapped packs and carton packs in high-speed production lines. Adopting Siemens PLC & HMI intelligent control, world-class electric and pneumatic components, the system realizes unmanned continuous stacking, stable pallet transportation and full safety interlock protection, ideal for high-capacity end-of-line packaging automation.
- Product Overview
- Video
- Machine Structure
- Working Process
- Photos
- FAQ
- Recommended Products
Product Overview
The robotic palletizer is a flexible automatic pallet stacking solution built around an industrial articulated robot. Different from gantry and low-level mechanical palletizers, the robot arm features large working envelope, outstanding motion flexibility and excellent multi-product adaptability.
Packaged goods delivered by upstream conveying equipment are grabbed by robot end effector, accurately positioned and stacked layer by layer on empty pallets following preset stacking layouts. The system stores multiple palletizing recipes, enabling quick switching between different carton sizes, film pack specifications and stacking modes without complicated mechanical adjustments.
The whole unit consists of robot main body, customized gripper, pallet feeding conveyor, product infeed conveyor, safety fencing and central control system. It can be integrated into new packaging lines or retrofitted into existing production workshops. After palletizing is finished, full pallets can be automatically transported to stretch wrapping stations for film packaging. It effectively replaces repetitive manual stacking, reduces workplace safety risks and brings stable, long-term unmanned operation for medium and mixed-variety production lines.
Video
Machine Structure
1.Robotic Unit
Robot Main Body
| Model | KUKA KR 180 |
| Wrist Payload | 180 kg |
| Maximum Reach | 3195 mm |
| Number of Axes | 4 |
| Protection Class | IP67 |
| Mounting Type | Floor-mounted |
| Repeat Positioning Accuracy | ±0.05 mm |
Electrical Connection
| Power Supply | 3-phase 400V (+10%, -15%), 50Hz |
| Rated Power | 13 KVA (Transformer Capacity) |
| Overall Robot Height | 2350 mm |
| Base Dimension | 1136 mm × 850 mm |
| Robot Weight | 1017 kg |
| Ambient Temperature | 0°C – 50°C |
| Relative Humidity | Up to 95% |
| Noise Level | <73 dB |
2.Speed Separation Belt Conveyor
Consists of two-stage belt conveyors with different linear speeds. The front belt runs faster than the rear belt, which automatically separates closely arranged cartons and packs to eliminate product collision during subsequent box sorting and grouping, ensuring orderly product arrangement and stable grabbing accuracy.
3.Product Layer Grouping Station
Equipped with professional box stopping, pushing and arranging mechanisms. According to the preset palletizing layout, the system automatically arranges single products into standard complete layers. The finished layered products are pushed to the collecting platform through the box pushing mechanism, providing accurate and orderly materials for robot gripper grabbing.
4.Custom Robot Palletizing Gripper
4.1 Gripper Working Principle
Adopts bottom-support grabbing structure. The inserting rods and clamping plates are driven by the main cylinder to move synchronously along the sliding rail, realizing stable supporting, clamping and releasing of carton products. The cylinder action stroke is programmatically adjustable to adapt to different product sizes and stacking layouts, realizing flexible multi-specification palletizing.
4.2 Gripper Structural Composition
Composed of robot flange connector, high-strength aluminum alloy main frame, stainless steel inserting rods and full set of pneumatic driving components. It features high structural strength, deformation resistance, stable clamping and long service life.
5.Automatic Empty Pallet Feeding System
Empty pallets are automatically separated by the pallet separator and stably transported to the robot palletizing station through roller conveyor. The pallet conveyor adopts carbon steel plastic-sprayed frame and support legs, Φ76mm heavy-duty rollers and 10B-1 chain transmission. Equipped with frequency converter soft start control to ensure zero-impact, stable and smooth pallet feeding without offset or jamming.
6.Full Pallet Discharging Conveyor System
The finished full pallet output conveyor adopts heavy-duty roller transmission structure, with carbon steel plastic-sprayed side plates and support legs. Supported by frequency conversion soft start technology, the conveyor runs stably without impact. Equipped with photoelectric automatic detection function, it automatically stops when blocked and starts when vacant. The conveyor load capacity is ≥1000kg, fully meeting long-term heavy-load pallet output requirements.
7.Safety Fence Protection System
The perimeter safety guardrail is welded with 5mm carbon steel round pipes with 50×50mm uniform grid spacing, fixed on the ground with expansion bolts to form a fully enclosed safety protection zone for the robot working area. A reserved safety door is installed on the incoming and outgoing side for daily maintenance and overhaul. The safety door is equipped with proximity switch interlock; the entire machine stops automatically once the door is opened, effectively protecting personnel and equipment safety.
8.Intelligent Control System
The control system consists of main power cabinet and independent operation cabinet, equipped with professional HMI human-machine interaction interface. The main electric cabinet adopts carbon steel plastic-sprayed body with external power knob switch for convenient and safe operation. It supports one-click start-stop, parameter modification, recipe storage, running status monitoring and fault alarm display.
Working Process
| Product Acceleration & Direction Adjustment | → | Product Layer Grouping & Arrangement | → | Robotic Palletizing | → | Full Pallet Discharge |
| ↑ | ||||||
| Pallet Conveying | ← | Pallet Separation |
Step 1: Finished packaged goods (semi-tray packs, cartons, film-wrapped bundles) are aligned and conveyed to the designated grabbing position within the robot working zone, and a ready signal is sent to the palletizing robot. Simultaneously, empty pallets are transported to the designated palletizing station via the automatic pallet conveying system.
Step 2: Upon receiving the trigger signal, the robot picks up the packaged goods and places them onto the pallet following the preset stacking pattern. Meanwhile, new packaged products (semi-tray packs, cartons, film-wrapped bundles) are continuously delivered to the robot grabbing area.
Step 3: The robot repeats the cycle of Step 1 and Step 2 for continuous automatic palletizing.
Step 4: Once pallet stacking is completed, the system outputs a finish signal. The fully loaded pallet is conveyed to the transfer position by the automatic pallet transport system, where operators can remove the full pallet with a forklift.
Photos
FAQ
Q1: Are you a trading company or a direct manufacturer?
A: We are a dedicated manufacturer with over 22 years of industry experience in beverage filling and packaging. Based in Zhangjiagang (only 2 hours from Shanghai), our factory is equipped with advanced technology to provide high-quality equipment at factory-direct prices. We warmly welcome you to visit our facility to see our machines in action.
Q2: What is the difference between robotic palletizer and gantry palletizer?
A: Robotic palletizer adopts articulated multi-axis robot arm with greater flexibility. It can serve multiple conveying lines and adapts to frequent product changes. Gantry palletizer features larger single-line processing capacity and suits mass production of single stable product. Customers can select according to product variety and line layout.
Q3: What products can the robotic palletizer stack?
A: It is suitable for regular packaged goods such as sealed cartons and film-wrapped bundled packs. We customize matching gripper structure based on your actual product shape, weight and surface hardness.
Q4: Can this robotic palletizer connect with carton sealer and stretch wrapper to form a complete automatic packaging line?
A: Absolutely. Reserved signal communication interfaces support linkage with upstream case packers, carton sealers and downstream pallet conveying & wrapping machines, realizing unmanned operation from packing to pallet wrapping.
Q5: Do you provide overseas installation and training?
A: Yes. We can arrange senior technicians to your factory for installation, commissioning and systematic operation & maintenance training, including bottle blowing process adjustment and common fault handling.
Q6: What is the warranty period?
A: We provide a 12-month whole machine warranty starting from the commissioning date, with lifetime technical support and long-term supply of original spare parts and wearing parts at factory price.
