What is Palletizing? 

Palletizing refers to the process of efficiently stacking products onto pallets for shipment or storage during logistics operations. It is an essential task performed in almost all production facilities. However, it is extremely difficult for humans to stack heavy products repeatedly and consistently. For this reason, many companies are choosing palletizing automation. Today, we will take a detailed look at palletizing automation and the robots that perform it with our robot expert, Brian.

Industrial robot stacking bags onto a pallet

Q1. Hello, Brian. Can you explain palletizing automation precisely? Brian: Yes, of course. Palletizing automation means automating the task of loading products onto pallets using various automation technologies such as industrial/collaborative robots, conveyor belts, and vision systems. Due to high-intensity work and safety reasons, palletizing automation is now becoming a necessity.

Q2. So we need something to perform the work instead of humans. Is that the robot? Brian: That’s right. By automating heavy and dangerous palletizing tasks with robots, you can ensure worker safety. Since they can work 24 hours a day without rest, you can shorten task times and improve productivity. You can also reduce costs through decreased labor expenses, reduced product damage, and shorter operation times.

The palletizing automation market is growing exponentially as it is a task required in many industries and one that negatively affects the health of workers. The market research firm Fact.MR estimates the current size of the global palletizing robot market, including both industrial and collaborative robots, at $4.136 billion (approx. 5.4 trillion KRW). This market is expected to grow at an average annual growth rate of 9.4%, reaching $10.156 billion (13.2 trillion KRW) by 2033. From 2018 to last year, it showed an average annual growth of 7.1%.

Click to check out global palletizing automation industrial robots at a glance.

Q3. Are companies actually building palletizing automation? Brian: Absolutely. Recently, Marosol, a total robot solution company, completed the construction of a car battery palletizing automation solution at the Hankook & Company Changwon plant in Gyeongnam. Since car batteries have different import pallet standards by country and various palletizing patterns designated by each customer, there were over 200 cases. It was a daunting task, but Marosol solved it through palletizing standardization for various pallets, patterns, and products. Through this palletizing automation, Hankook & Company was able to see a rise in workload and a reduction in labor costs by reducing the number of personnel per line from 4 to 1. You can find more details by clicking the image below.

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Q4. How is palletizing automation carried out? Brian: First, palletizing work follows the sequence of: Product collection -> Pallet preparation -> Product stacking -> Securing -> Labeling. The parts where automation takes place are the Product stacking and Securing sections. When the robot detects products coming off the conveyor belt and stacks them neatly on a pallet, a sealing process uses plastic wrap or tape to secure the stacked items so they don't shake.

Robot stacking items from a conveyor belt Wrapping items loaded on a pallet

Q5. What robots are used for palletizing automation? Brian: The most commonly used robots for automating palletizing tasks are industrial robots. Industrial robots can easily lift items of a weight that is impossible for humans to carry, and they are also fast. Because of this, palletizing is one of the processes where industrial robots are most frequently introduced. If you click the image inserted below, you can see a robot stacking 12 beverage boxes (40kg each) per layer for 9 layers (108 total), which is difficult for a human to lift, in less than 3 minutes.

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Q6. Is there a robot brand optimized for palletizing automation among industrial robots? Brian: Representative industrial robots for palletizing automation include Hyundai Robotics and Yaskawa. I’ll explain Yaskawa first.

Yaskawa, a representative Japanese robot manufacturer, is a company with annual sales of approximately 474.6 billion yen (as of 2023) and ranked 5th in global market share (as of 2023). The reason Yaskawa is confident in palletizing automation is that it has accumulated over 40 years of experience and know-how since entering the palletizing robot market in the early 1980s.

Yaskawa is so serious about palletizing automation that they even created dedicated palletizing software. PalletSolver, a simple software that can generate ideal palletizing patterns, simplifies the required palletizing processes and supports the robot in performing palletizing tasks more efficiently. Once PalletSolver is installed, you can set pallet patterns and robot motions on a PC, and no separate offline teaching is required.

Q7. Please provide a detailed explanation with an actual case study of Yaskawa industrial robots.

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Brian: This application case involves using the YASKAWA GP180 to stack boxes of clothes hanger products weighing over 20kg onto pallets. You can see the process where the industrial robot picks up products supplied by the conveyor belt and organizes them on a pallet. In the video, you can see a general worker, not a robot expert, easily operating the robot. You can see that ease of use and programming is a characteristic of Yaskawa industrial robots.

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This application case also implemented palletizing tasks automatically using the YASKAWA GP180. A unique point is that it involves identifying and stacking two types of products. By replacing robots in a process where workers avoided handling 1.5kg products at around 80°C, worker satisfaction increased, fatigue was reduced even with many processes per person, and the site environment, such as organization, was improved.

Q8. Please introduce Hyundai Robotics as well. Brian: Hyundai Robotics is a leading domestic industrial robot manufacturer recognized in domestic and international markets based on high technology and competitiveness. In particular, it holds the No. 1 market share in Korea in the field of palletizing automation and is securing future growth engines by actively investing in service robots and automation systems. The reason Hyundai Robotics could hold the No. 1 market share in Korea is that they not only have the durability, high precision, and payload of Kawasaki industrial robots but also have a variety of models with different sizes and functions, allowing customers to choose the optimal robot for their needs.

Q9. Can we see an actual case study video of palletizing automation with Hyundai Robotics industrial robots?

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Brian: This application case is a solution for palletizing paper bags by integrating a self-developed OP system with the Hyundai Robotics HS220. The self-developed OP system can be used efficiently by flexibly setting it according to pallet size and packaging material characteristics. Particularly, based on years of experience in supplying bag manufacturing equipment, we realized a palletizing system that operates stably in the workplace. By installing two Hyundai Robotics HS220 units with a payload of 20kg to implement palletizing automation, it is said that production output increased significantly. Previously, when workers performed palletizing, it was hard to increase production even if orders piled up, but thanks to automation, they can now handle any amount of orders without issues.

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The next case study involves using the Hyundai Robotics YS080L to stack pharmaceutical boxes on pallets and perform wrapping. As an optimized package solution performed by KT, it can be introduced at a low cost, and by linking it with KT’s own smart factory platform, Factory Makers, the smart factory system could be introduced along with the automation solution. By using the KT Smart Factory solution, it is possible to monitor robot status and events, send alarms (SMS), link data on operation figures, and enable efficient operation through production volume inquiry.

You can learn more about industrial robots from around the world, including Hyundai Robotics and Yaskawa, at Marosol. Click the button below to check everything from quotes to case studies! 👇👇👇

Click to check out global palletizing automation industrial robots at a glance.

Q10. Finally, please share if there is a way to build palletizing automation most reliably! Brian: I recommend inquiring about palletizing automation with Marosol, a total robot solution company. To successfully build palletizing automation, you need robot experts with a lot of related data and construction experience. Marosol has robot experts with over 30 years of outstanding capabilities in the field of palletizing automation and can provide customized solutions tailored to customer needs in various industrial fields (food, beverage, chemical, pharmaceutical, etc.).

Furthermore, at Marosol, you can find robot automation at the lowest price. To solve the price issue, Marosol developed the first robot financial products, allowing you to purchase robots through leases, rentals, and 12-month interest-free installments. Also, by purchasing robots in bulk from manufacturers, solutions can be implemented at the industry's lowest price.

Marosol robot expert conducting a consultation at the 2023 SFAW exhibition.

If you want to build palletizing automation perfect for your factory but can’t picture how to replace it systematically, or if you have a process concept but are looking for a company that can realize it economically, Marosol, a total robot solution specialist, can be the solution. Marosol is available for consultation at any time, so please contact us at 080-858-5050 at your convenience, or click the image below to visit the Marosol website and leave an inquiry. We will assist you as soon as possible. 👇👇👇

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