| 1 |
Select the robot type according to the palletizing pattern |
Robot architecture and motion requirements |
Use a six-axis articulated robot when products require flexible orientation, mixed-SKU handling, or access from several directions. Use a four-axis palletizing robot when high-speed, repetitive layer stacking is the main requirement. |
Four-axis robots are commonly used for dedicated, high-throughput palletizing. Six-axis robots provide greater orientation flexibility but usually require more programming and floor space. |
Confirm the number of product types, required approach angles, pallet layout, layer pattern, and whether future product variants will be introduced. |
| 2 |
Calculate payload using the complete moving load |
Rated payload, product weight, end-effector weight, and safety margin |
Calculate payload as product weight plus gripper, brackets, hoses, sensors, and any carried packaging. Do not size the robot using product weight alone. |
For a 25 kg product and a 10 kg gripper assembly, the robot must carry at least 35 kg before applying an engineering margin. Actual allowable payload also changes with wrist moment and center of gravity. |
Request the manufacturer’s payload chart for the intended wrist posture, center of gravity, moment, inertia, and planned acceleration. |
| 3 |
Choose reach from the complete cell layout |
Horizontal reach, vertical stroke, pallet position, and conveyor height |
Measure the distance from the robot mounting point to the farthest product pickup point and the farthest pallet corner. Include pallet height, layer height, safety clearance, and access for maintenance. |
Many palletizing applications use robot reaches of approximately 2,000–3,200 mm, but the correct value depends on product dimensions, pallet size, conveyor location, and robot installation height. |
Check reach at the most difficult pickup and placement positions, not only at the center of the working envelope. |
| 4 |
Match cycle time to the required throughput |
Cases per hour, picks per minute, layer time, and product changeover time |
Determine the required rate from actual production demand. Include conveyor indexing, product separation, barcode or vision checks, pallet changes, and occasional recovery actions. |
Throughput is influenced by product weight, travel distance, stacking pattern, acceleration, and whether one or multiple products are picked per cycle. A nominal robot speed does not equal guaranteed system throughput. |
Ask for a cycle-time simulation or acceptance test using representative products, pallet patterns, conveyor speeds, and the intended end effector. |
| 5 |
Specify the end effector for the product surface and load stability |
Gripper type, gripping force, contact area, product variability, and release behavior |
Vacuum grippers suit many cartons with sufficiently smooth, nonporous surfaces. Mechanical clamps or fork-style tools are better when surfaces are porous, uneven, dusty, damaged, or unsuitable for vacuum pickup. |
Vacuum performance depends on seal quality, leakage, altitude, filter condition, and surface porosity. Mechanical gripping force must be sufficient for acceleration and emergency-stop conditions without crushing the product. |
Test the weakest carton, smallest package, damaged package, wet or dusty surface, and maximum allowable product deformation. |
| 6 |
Confirm pallet and layer compatibility |
Pallet dimensions, load height, layer count, pattern, and overhang limits |
Define the pallet footprint, usable pallet area, product orientation, interlocking pattern, maximum stack height, and whether slip sheets or top frames are required. |
Common pallet footprints vary by region, including approximately 1,200 × 800 mm, 1,200 × 1,000 mm, and 1,219 × 1,016 mm. The selected pattern must be validated against product dimensions and stability requirements. |
Verify local pallet standards, forklift entry, pallet quality, load overhang rules, and the final center of gravity of the completed load. |
| 7 |
Design for product and pallet changeovers |
SKU count, recipe management, tool changes, and changeover duration |
For multiple products, use stored recipes with adjustable pickup positions, product dimensions, layer patterns, and conveyor timing. Automatic tool change may be justified when products require substantially different gripping methods. |
Recipe-based changeover reduces manual adjustment, but each recipe still requires validation for collision clearance, grip reliability, pallet stability, and safe restart behavior. |
Request the maximum number of recipes, password-controlled settings, barcode or communication options, and the expected changeover procedure. |
| 8 |
Check repeatability, accuracy, and process tolerances |
Robot repeatability, conveyor position accuracy, package dimensional variation, and pallet placement accuracy |
Robot repeatability alone does not guarantee accurate palletizing. The complete system must control product presentation, conveyor stopping, pallet location, gripper deflection, and carton dimensional variation. |
Industrial robot repeatability is often specified in millimeters, while real palletizing accuracy depends on the integrated cell and can be lower than the robot’s laboratory specification. |
Define acceptable carton offset, pallet edge clearance, layer alignment, and test conditions. Review the applicable robot performance standard and supplier measurement method. |
| 9 |
Evaluate installation, utilities, and environmental conditions |
Floor loading, mounting orientation, temperature, dust, moisture, compressed air, and electrical supply |
Confirm whether the robot is floor-mounted, elevated, or wall-mounted. Check foundation stiffness, enclosure rating, ambient temperature, washdown requirements, compressed-air quality, and local electrical requirements. |
Many general industrial robots operate within a controlled indoor temperature range, while food, chemical, dusty, or washdown environments may require enhanced protection and compatible materials. |
Verify ingress-protection requirements, air pressure and consumption, voltage and frequency, grounding, cable routing, and regional safety regulations. |
| 10 |
Include safety, serviceability, and total cost of ownership |
Safety functions, guarding, access, spare parts, training, maintenance, and energy consumption |
Plan the cell around risk assessment, guarded access, safety-rated stop functions, interlocks, emergency stops, safe restart, and clear maintenance access. Compare lifecycle cost rather than purchase price alone. |
A complete palletizing cell may include the robot, controller, gripper, conveyors, pallet dispensers, stretch wrapping, guarding, sensors, software, installation, validation, and operator training. |
Ask for safety documentation, preventive-maintenance intervals, spare-parts lead times, remote-support capability, software licenses, warranty terms, and acceptance-test criteria. |
