APPLICATION-FIRST AUTOMATION:

How to Succeed
with PalletizingeBook
Published June 2022

Workpiece

Collaborative Automation
Starts with Your UniqueApplication Needs
Environment

These days, workers are in short supplyand product demand is high. Thatmeans you can’t afford to miss customer
deliveries simply because you can’t
staff repetitive, unergonomic tasks likepalletizing.

System requirements

Palletizing using collaborative or lightindustrial robots provides fast returnon investment (ROI) even for small andmidsized manufacturers and logistics
organizations. It’s cost-effective, quickto deploy, and offers the flexibility
needed for high-mix, low-volume
environments and peaks in demand.
You get better consistency and higher
productivity without overtime orinjuries. And with automated palletizing

you can depend on, you can focus on
staffing more desirable, higher-value
positions for workers to help you growyour business.
The challenge is to find the rightpalletizing system that meets yourunique business needs, now and into thefuture. That means technology choices
shouldn’t drive your decisions. Instead,your application needs should guide youto the best solution. This applicationfirst approach is the key to successfully
deploying your automated palletizing
system quickly, reliably, and costeffectively.

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Anatomy of aCollaborative
Palletizing System
While collaborative palletizing systems can be configured in manyways, a typical system includes most or all of these elements:• Infeed conveyor with sensors to detect the presence of boxes• Collaborative or light industrial 6-axis robot• Lift (7th axis) to extend robot reach• Vacuum or finger gripper with ability to handle slip sheets• Slip sheet stack fixture with sensor to detect slip sheet presence• Pallet fixture with sensors to detect pallet presence• Programming and monitoring software to integrate and manage
entire system
Palletizers are often deployed by a system integrator, but if thepalletizer system elements you choose are designed to work together,
deployment will be simpler, faster, and less expensive. And you havethe option of redeploying and managing the system on your own,even without extensive robotics experience.

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Workpiece Requirements
Your application decision starts with the size, shape, weight, and type ofcontainers, boxes, or other packaging that you need your palletizer tohandle. It’s also important to think about workpiece changes that may
occur in the future to make sure your palletizing system can keep up
with your business as it evolves and grows.

Euro containers(Plastic KLT boxes)

Closed cardboard boxes

The other critical workpiece decision is the type and size of pallet andpalletizing pattern. This may also change over time as your businessevolves or as customer requirements change, making flexibility andconfigurability key elements for success.

Packs of bottles

Lidless and open boxes,
shelf-ready products

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Workpiece Considerations
PayloadPorosity

Shape

Slip sheet

Size and weight of boxes or packages
influences robot and gripper
specifications, but can also havean impact on worker safety. Heavyboxes may not meet risk-assessment
guidelines for collaborative
applications, so the system may
require additional safety features.

Lighter-weight cardboard can be lessexpensive but is also more porous.
Vacuum grippers vary widely in theirability to successfully grip porous
cardboard, so check specifications.

The shape or material of the box
affects the best way to grip them.
Traditional closed boxes are ideal
for vacuum grippers, while open
containers, plastic KLT boxes, andother types of packages may be more
appropriate for finger grippers.

If your application requires slip sheets,look for a gripper that can handle
both boxes and slip sheets, and withautomated programming to make thisstep seamless.

Variability
Variability in size can also affectyour choice of robot, and whether
you can use the same gripper for
multiple sizes of boxes or if you’ll
need multiple grippers to meetdifferent applications.

Multiple workpieces
You may get higher overall output if
you can move multiple boxes at once.
A powerful and customizable vacuum
gripper offers additional flexibility forthis option.

OnRobot eBook | Application-First Automation | How to Succeed with Palletizing | 5Environment Requirements
Your collaborative palletizing system should be flexible enough to fit into your existing floor
plan and production workflows with minimal disruption. Early palletizing systems typicallyoffered limited configuration for placement of the robot and pallets in front of the infeed
system, but new advancements offer more flexibility.

InfeedOutfeed
Pallet A

Robot

Outfeed
Pallet B

Slip SheetThe OnRobot Palletizer offers multiple layout options to match workflow needs and fit
into existing palletizing workcells.
InfeedInfeedInfeedInfeedOutfeed
Pallet A

Outfeed
Pallet A

Robot

Outfeed
Pallet ARobot

Outfeed
Pallet A

Outfeed
Pallet A

Robot

Slip Sheet
One Pallet

Two Pallet

One Palletwith Slip Sheet

Robot

Slip Sheet
Outfeed
Pallet B

Two Palletwith Slip Sheet

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Environment
Considerations
Be prepared for questions your system integrator will ask aspart of researching your options. Your answers will help guidethe best choice for your situation.
Will your automated palletizing system fit in yourexisting palletizing space without moving yourinfeed system?
Is the space adequate for the robot arm to reachthe conveyor and pallet(s) without encountering
obstacles or being a safety hazard for workers?
How many active pallets do you need, and where
do they need to be placed with respect to your infeedsystem?
How and when will full pallets be removed andexchanged for empty ones?
Where and how often will workers need to enter
the palletizing cell?

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SystemRequirements
Palletizing system requirements are defined by your business needs,
now and into the future. By taking an application-first approach, you
dramatically improve the likelihood that the system will continue
to meet your changing needs, boosting productivity and speeding
ROI. That approach is especially important for small and midsizedenterprises (SMEs) with high-mix, low-volume operations, limited inhouse automation expertise, and tight budgets.
In these situations, software becomes a critical element of theoverall system. Powerful, intuitive palletizing software means lower
integration costs and faster time-to-production. Reprogramming for
new products, a different gripper, or to meet changing pallet size,
type, or pattern can be done quickly in-house, even with minimal
robot experience. And software that is capable of monitoring all
elements of the system helps enhance productivity and reliability andminimize downtime.

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System Considerations

Gripper• Determined by workpiece assessment.
• Flexible collaborative grippers
eliminate customization costs and givelong-term reliability.

Pallet Stationsand Slip Sheets• Electric grippers eliminate thecost and space requirements ofcompressed air.

• Determine numberand placementof pallets and slip
sheets, if required.

Robot• Maximum payload includes bracket,gripper, and workpiece and impacts
reach.
• Horizontal and vertical reach mustcover entire pallet. Note that smaller
boxes require larger reach.

Software• Intuitive programming speeds deployment
and allows in-house changes for new
products or palletizing requirements.
• Single software solution to manage allsystem elements allows fast, easy changes.
• Monitoring software optimizes programfor reliability and output and alerts formaintenance requirements.

Lift• Cycle time requirements may put
robot speed outside collaborativelimits and require safety guarding.

• Height of stackand robot reachdetermine if lift
(7th axis) is needed.

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Out-of-the-Box
Palletizing
An integrated, configurable, out-of-the-box palletizing
system is an ideal application-first approach. You
get the flexibility to define your system around yourunique business needs, but with all the benefits of asingle vendor.

Succeed with OnRobot
Application-First Palletizing
Software7th axis

Pallet Fixture

RobotGripper

Results:• Faster deployment and easier changeovers• Fits into existing layout and workflows

OnRobotPallezixng

1xPallet Station

2FGP202xPallet Station

VPG20• Lowers total costs and speeds ROI• Future-proof for evolving business needs• Fully tested, certified, and warrantied for reliability

Lift100WebLytics

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Talk to the experts
in applicationfirst automation.
Speed your path to palletizing success.
Learn more about the flexible, intuitive,and cost-effective OnRobot Palletizer.

TALK TO AN EXPERTAbout OnRobot
OnRobot is the right choice for manufacturers who want thebenefits of collaborative automation to build a resilient, productive
business. No matter what process you need to improve, OnRobot
can help you automate swiftly and seamlessly. With all the tools youneed from one partner, you can focus on your business needs andmanufacturing processes. You’ll save costs and increase productivity
while growing your business with flexible automation tools, unified
programming, and easy deployment.
One stop, one system, zero complexity.
Headquartered in Odense, Denmark, OnRobot also has offices
in Dallas, Soest (Germany), Barcelona, Shanghai, Tokyo, Seoul,
Singapore and Budapest.
For more information visit: www.onrobot.com
Or contact us: sales@onrobot.com