Mastering Robotic Palletizing: 5 Essential Principles for Optimal Performance
Aug 16,2025
Implementing a robotic palletizing solution using a palletizing robot can not only help your production operations run as smoothly as possible, but also help increase speed, output and reduce costs.
It is well known that automation is going to impact the future of manufacturing massively. It already is helping businesses all over the world redesign their processes, maximize their output and grow in the face of a global shortage of labor. But knowing how beneficial automation can be is not the same as knowing how to implement a robotic palletizing solution effectively.
Getting the most value out of your palletizing robot as quickly as possible requires preparation and sticking to some basic principles. Here are our top five rules for robotic palletizing:
1.Understand your payload
It may sound simplistic, but you need to make sure your chosen palletizing robot can carry out the palletizing tasks you want it to. When it comes to payload, this means thinking carefully about the weight of the packages and products being moved as well as the throughput of the conveyor. You might need your palletizing robot to handle multiple boxes at the same time, which can, in turn, require a higher payload.
Also, don’t forget to include in your calculations the weight of the grippers you will be using. It will help ensure you get the best performance possible.
2. Choose the right gripper
Your palletizing robot is only as good as its end effector, otherwise known as its end-of-arm tooling or gripper. Making sure you have the right one is crucial to the success of your project. There are a couple of things to consider here. First, the kind of cardboard your products are packed in will mean that only some types of grippers are suitable, particularly for wrinkled or more lightweight packaging.
Second, you need to factor in the work rate of your palletizing robot and its working environment. If you are going to push your robotic palletizing system to its payload limits consistently for long stretches every day, opting for lighter grippers can help reduce wear and tear. Some grippers will also need an external power source.
3. Measure your footprint
Floorspace is one of the most important assets in a production line and one that is always limited and in demand. SZGH new All-In-One robot is having smaller footprint, integrated design, saving customer site space, and overall easier to move which is suitable for limited area to work. This is the advantage over other kinds of industrial robots, especially when it comes to palletizing. The small footprint of the palletizing robot makes it much easier to design a really space efficient palletizing operation.
4. Get to grips with stack patterns
No two palletizing operations are ever the same. This means you will need to make sure the stack patterns you use are the right ones. You will need to do your pallet stacking to the maximum height that can fit into freight trucks and containers. Your stack patterns are important as they dictate how much product fits each pallet and how stable each completed pallet is.
Designing your own stack patterns can be complex. It involves translating the pallet stacking pattern into coordinates for the robot. Luckily, there are lots of software and application kits available that allow users to design and edit their own stack patterns without the need to write a single line of code. These software solutions are invaluable when it comes to democratizing the benefits of automation because they allow users with minimal automation experience and training to jump in and have a go.
5. Optimize your safety
You should always complete a thorough risk assessment before implementing your cobot. In particular, you want to be sure that it is safe for workers and machines to work closely with regards to sharp edges and moving heavy payloads at speed.
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