Palletizing System Design

Understanding Palletizing Systems in Modern Manufacturing

In today's competitive manufacturing landscape, efficient material handling represents one of the most significant opportunities for operational improvement. Palletizing systems—the automated solutions that arrange products onto pallets for storage and shipping—have become essential infrastructure for companies looking to increase throughput, reduce labour costs, and improve workplace safety. For manufacturers across Atlantic Canada, from food processing facilities in Nova Scotia to lumber operations in New Brunswick, implementing the right palletizing system can transform end-of-line operations.

At their core, palletizing systems must accomplish a deceptively complex task: taking individual products or cases and arranging them into stable, efficient pallet loads that can withstand the rigours of transportation and storage. This requires careful consideration of product characteristics, throughput requirements, facility constraints, and integration with existing production lines. A well-designed palletizing system can handle anywhere from 5 to 200 cases per minute, depending on the technology employed and the specific application requirements.

Types of Palletizing Systems and Their Applications

Selecting the appropriate palletizing technology requires a thorough understanding of the available options and their respective strengths. Each system type offers distinct advantages depending on production volumes, product characteristics, and budget considerations.

Conventional Layer Palletizers

Conventional layer palletizers remain the workhorse of high-volume operations, particularly in industries such as beverage bottling, canning, and consumer packaged goods. These systems use mechanical row-forming devices to arrange products into complete layers, which are then placed onto pallets in a single motion. Modern layer palletizers can achieve speeds of 80 to 150 cases per minute, making them ideal for facilities with consistent, high-volume production runs.

The mechanical nature of these systems provides exceptional reliability, with many installations operating continuously for 15 to 20 years with proper maintenance. However, they require significant floor space—typically 6 to 10 metres in length—and are best suited for operations with limited product variety, as changeovers can take 30 minutes or more.

Robotic Palletizing Systems

Robotic palletizers have gained tremendous popularity over the past decade, offering flexibility that conventional systems cannot match. These systems typically employ articulated arm robots with 4 to 6 axes of motion, equipped with specialized end-of-arm tooling designed for specific product types. Modern robotic palletizers can handle 12 to 30 cycles per minute, translating to throughputs of 20 to 60 cases per minute depending on layer patterns and pallet configurations.

The primary advantage of robotic systems lies in their flexibility. A single robot can handle multiple product types, pallet patterns, and even multiple production lines through proper cell design. This makes robotic palletizing particularly attractive for Maritime manufacturers dealing with seasonal production variations or diverse product portfolios. Additionally, robotic systems typically require 30 to 50 percent less floor space than conventional alternatives.

Collaborative Robot (Cobot) Palletizers

For lower-volume applications or facilities with significant space constraints, collaborative robots offer an increasingly viable solution. Cobots are designed to work safely alongside human operators without traditional safety guarding, provided they operate within specified force and speed limits. Typical cobot palletizers handle 6 to 12 cases per minute, making them suitable for operations currently performing manual palletizing with 1 to 3 workers.

The payload capacity of cobots has improved significantly, with current models offering lift capacities of 16 to 35 kilograms. This accommodates most case sizes found in food processing, pharmaceutical, and consumer goods applications common throughout Nova Scotia and the broader Atlantic region.

Critical Design Considerations for Palletizing Systems

Successful palletizing system implementation requires careful attention to numerous design factors that influence both initial performance and long-term operational success. Engineering firms must analyse these considerations systematically to develop solutions that meet current requirements while accommodating future growth.

Product Characteristics and Handling Requirements

Every palletizing system design begins with a comprehensive analysis of the products to be handled. Critical parameters include:

• Dimensions and weight: Case sizes typically range from 200mm x 150mm x 100mm to 600mm x 400mm x 400mm, with weights from 2 to 35 kilograms

• Packaging material: Corrugated cases, shrink-wrapped bundles, bags, pails, and trays each require specific handling approaches

• Product fragility: Determines acceleration limits, gripper pressure settings, and layer placement speeds

• Surface characteristics: Influences vacuum cup selection, friction pad requirements, and slip sheet usage

• Temperature conditions: Frozen products, for instance, may require heated vacuum cups and specialised lubrication

For Atlantic Canadian food processors handling seafood products, temperature considerations become particularly important. Frozen fish cases may exit processing at -20°C, requiring end-of-arm tooling designed for cold environments and potential condensation management.

Throughput and Cycle Time Analysis

Accurate throughput calculations form the foundation of proper system sizing. Engineers must account for peak production rates, future capacity expansion, and acceptable buffer times between upstream processes and palletizing operations. A comprehensive analysis considers:

• Average production rate in cases per minute

• Peak production rates and their duration

• Number of SKUs and changeover frequency

• Pallet pattern complexity and layer configurations

• Empty pallet staging and full pallet removal times

For example, a fish processing facility producing 40 cases per minute requires a palletizing system capable of sustaining at least 48 to 50 cases per minute to account for production surges and prevent upstream line stoppages. This 20 percent safety margin represents standard industry practice for reliable operation.

Facility Integration and Layout Optimization

Palletizing systems must integrate seamlessly with existing facility infrastructure, including incoming conveyors, stretch wrappers, pallet dispensers, and material handling equipment. Key integration considerations include:

• Infeed conveyor design: Accumulation length, product orientation, and speed matching requirements

• Outfeed configuration: Conveyor versus forklift removal, stretch wrapper integration, and staging requirements

• Utility requirements: Electrical supply (typically 480V three-phase in Canada), compressed air (5 to 7 bar), and network connectivity

• Floor loading: Robot bases may impose point loads of 20,000 to 50,000 N, requiring structural assessment

• Ceiling height: Minimum requirements of 4 to 5 metres for standard pallet heights with adequate robot clearance

End-of-Arm Tooling Design and Selection

The end-of-arm tool (EOAT) represents perhaps the most critical component in any robotic palletizing system. This interface between robot and product must reliably grip, transport, and place products thousands of times per shift without damage or failure. Proper EOAT design directly influences system speed, reliability, and product quality.

Vacuum-Based Grippers

Vacuum grippers dominate palletizing applications, offering gentle handling suitable for corrugated cases and shrink-wrapped products. Modern vacuum systems use foam-sealed cups or bellows-style cups connected to venturi generators or vacuum pumps. Design considerations include:

• Cup diameter and quantity based on case dimensions and weight

• Vacuum level requirements (typically -60 to -80 kPa for reliable gripping)

• Foam seal selection based on surface texture and porosity

• Vacuum monitoring and loss-of-grip detection systems

For operations in humid Maritime environments, vacuum system design must account for moisture in compressed air supplies. Proper air treatment with coalescing filters and desiccant dryers prevents performance degradation and extends cup life.

Mechanical Grippers and Clamp Systems

Mechanical grippers excel in applications involving pails, drums, bags, or products with irregular surfaces unsuitable for vacuum handling. These systems use pneumatic or servo-driven clamps to secure products during transport. Clamp force must be carefully calibrated—sufficient to prevent slippage during robot motion while avoiding product damage.

Advanced mechanical grippers incorporate force feedback and compliance features that allow adjustment during operation. This proves particularly valuable for bag palletizing applications, where fill levels may vary and excessive clamping force could cause product damage.

Control Systems and Software Architecture

Modern palletizing systems rely on sophisticated control architectures that coordinate robot motion, conveyor operation, safety systems, and upstream/downstream equipment. Well-designed control systems maximise throughput while providing operators with intuitive interfaces and comprehensive diagnostic capabilities.

PLC and Robot Controller Integration

Most palletizing cells utilise a hierarchical control structure with a central PLC coordinating cell-level functions and dedicated robot controllers managing motion execution. Communication between these controllers typically occurs via industrial Ethernet protocols such as EtherNet/IP or PROFINET, with cycle times under 10 milliseconds ensuring responsive coordination.

The PLC handles functions including conveyor control, product detection and tracking, pallet pattern selection, safety system monitoring, and communication with plant-level systems. Robot controllers execute motion profiles, manage end-of-arm tooling, and provide detailed fault diagnostics.

Pattern Generation and Recipe Management

Efficient palletizing requires optimised pallet patterns that maximise pallet density while ensuring load stability. Modern palletizing software includes pattern generation tools that calculate optimal arrangements based on case dimensions, pallet size, and maximum stack height. Key features include:

• Automatic pattern optimisation algorithms

• Pattern library management with quick changeover capability

• Integration with enterprise resource planning (ERP) systems

• Production tracking and reporting functions

• Remote monitoring and diagnostic access

For facilities handling multiple products—common in Nova Scotia's diverse food processing sector—recipe management systems enable changeovers in under 60 seconds, minimising production interruptions during SKU transitions.

Safety Systems and Regulatory Compliance

Palletizing systems must comply with Canadian safety standards, including CSA Z432 (Safeguarding of Machinery) and CSA Z434 (Industrial Robots and Robot Systems). Proper safety system design protects workers while maintaining operational efficiency.

Guarding and Access Control

Traditional palletizing cells employ perimeter guarding with access doors equipped with safety interlocks. Modern systems increasingly utilise safety-rated laser scanners and light curtains that allow more compact cell designs while maintaining required protection levels. Key safety components include:

• Safety-rated area scanners for perimeter monitoring

• Interlock switches on access doors and gates

• Emergency stop devices positioned throughout the cell

• Safety PLCs or safety-rated robot controller functions

Risk Assessment and Documentation

Canadian regulations require formal risk assessments for robotic systems, documenting identified hazards and implemented safeguards. This documentation becomes particularly important for facilities subject to workplace safety inspections or those pursuing quality management certifications. Professional engineering firms ensure all designs meet or exceed applicable standards while providing comprehensive documentation for regulatory compliance.

Return on Investment and Implementation Considerations

Palletizing automation typically delivers compelling returns for facilities currently relying on manual operations. Labour savings represent the primary benefit, but comprehensive ROI analysis must also consider factors such as reduced product damage, improved pallet quality, decreased workplace injuries, and increased throughput capacity.

For a typical Maritime manufacturing facility replacing manual palletizing with an automated system, investment recovery periods of 18 to 36 months are common. A facility operating two shifts with three manual palletizers might invest $350,000 to $500,000 in a robotic palletizing cell, with annual labour savings of $150,000 to $200,000 generating attractive payback periods even before considering secondary benefits.

Implementation timelines for palletizing projects typically span 4 to 8 months from engineering approval to full production, depending on equipment lead times and integration complexity. Phased implementations can minimise production disruptions, with temporary manual operations maintained until automated systems achieve full validation.

Partner with Sangster Engineering Ltd. for Your Palletizing System Design

Designing and implementing an effective palletizing system requires expertise spanning mechanical engineering, controls integration, safety system design, and project management. Sangster Engineering Ltd., based in Amherst, Nova Scotia, brings decades of automation experience to manufacturers throughout Atlantic Canada and beyond.

Our engineering team works closely with clients from initial concept development through commissioning and ongoing support, ensuring palletizing systems deliver sustained performance improvements. Whether you're considering your first automation investment or upgrading existing equipment, we provide the technical expertise and regional understanding needed for successful project outcomes.

Contact Sangster Engineering Ltd. today to discuss your palletizing requirements and discover how automation can enhance your operations. Our team is ready to analyse your specific application and develop solutions tailored to your production goals, facility constraints, and budget considerations.

Partner with Sangster Engineering

At Sangster Engineering Ltd. in Amherst, Nova Scotia, we bring decades of engineering experience to every project. Serving clients across Atlantic Canada and beyond.

Contact us today to discuss your engineering needs.