{"id":30186,"date":"2024-05-07T07:00:30","date_gmt":"2024-05-07T12:00:30","guid":{"rendered":"https:\/\/www.cisco-eagle.com\/blog\/?p=30186"},"modified":"2025-08-05T09:46:54","modified_gmt":"2025-08-05T14:46:54","slug":"palletizers-robotic-vs-conventional","status":"publish","type":"post","link":"https:\/\/www.cisco-eagle.com\/blog\/2024\/05\/07\/palletizers-robotic-vs-conventional\/","title":{"rendered":"Palletizers: Robotic vs. Conventional"},"content":{"rendered":"<p><img decoding=\"async\" style=\"width: 100%; max-width: 700px; height: auto; margin-bottom: 2px;\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/04\/robotic-vs-layer-palletizer.jpg\" alt=\"photo of side by side robotic arm palletizer and layer bag palletizer systems\" \/><\/p>\n<p>Palletizers are great for higher-volume operations. They increase palletizing speed, increase safety, and build solid, consistent pallets without human intervention. In today&#8217;s tough labor market, palletizing is one of the best places to automate and reduce manual involvement. Fully-automated systems come in two basic varieties: conventional and robotic, either of which could be the right fit for your operation.<\/p>\n<p><!--more--><\/p>\n<aside style=\"padding: 10px 20px 15px 25px; margin-bottom: 50px; border-radius: 15px; border: 2px solid #E4DDDD; margin: 4px 10px 4px 10px; box-shadow: 0 4px 8px 0 rgba(0, 0, 0, 0.2), 0 6px 20px 0 rgba(0, 0, 0, 0.19);\" data-type=\"summary\">\n<h4>TL;DR \u2013\u00a0 Choosing between robotic and conventional palletizers<\/h4>\n<p>Robotic palletizers offer flexibility, SKU variety handling, and easier integration, while conventional palletizers provide faster throughput and better results for consistent loads. Your best fit depends on the mix of products, volume, speed requirements, floor space, and operational goals. This post breaks down both systems. from effector types to maintenance demands, so you can make the right decision for your operation.<\/p>\n<\/aside>\n<h3>Robotic vs. layer palletizing systems: what you need to know<br \/>\n<iframe loading=\"lazy\" src=\"https:\/\/www.cisco-eagle.com\/video\/frame.aspx?id=967\" width=\"640\" height=\"360\" frameborder=\"0\" scrolling=\"no\"><span data-mce-type=\"bookmark\" style=\"display: inline-block; width: 0px; overflow: hidden; line-height: 0;\" class=\"mce_SELRES_start\">\ufeff<\/span><\/iframe><\/h3>\n<blockquote><p><em>Above: a brief video breakdown: the critical differences between robotic and layer palletizing systems<\/em><\/p><\/blockquote>\n<h4>Load types and profiles<\/h4>\n<p>Both systems can deal with boxes, bales, boxes, trays, crates and other defined loads, but robotic systems handle more types of loads than conventional ones. They are less demanding of rigidity and standardization. Robots, with a variety of end effectors, can handle things like drums that conventional systems struggle to deal with.<\/p>\n<h4>SKU variation, condition and quantities<\/h4>\n<p>Conventional palletizers lean into a defined process with a defined SKU or load type. If your system is running a single item through the palletizer, conventional tends to be the choice. Robotic systems, however, handle multiple SKUs and load sizes.<\/p>\n<p>Conventional systems process easily defined, rigid, stacked and layered items. If your SKUs are less uniform, robotic systems are the best option. If your operation prioritizes versatility and modularity, choose robotic systems. For consistent speed, though, layer systems are the clear winner.<\/p>\n<h4>Speed and throughput factors<\/h4>\n<p>Automated systems always palletize more units than any manual equivalent in far less time. They can build bag pallets at up to 4o bags per minute, or 80 cases per minute.<\/p>\n<p>Conventional palletizers are faster than robotic systems. When your process is consistent, with a single pallet of a single load, layer systems are a clear choice. They deliver fast, uniform pallets. Robotic systems are the choice for pallets of mixed SKUs, or SKUs that aren&#8217;t as consistent.<\/p>\n<h4>Integration with other systems and machinery<\/h4>\n<p>Robotic palletizers tend to lend themselves to up-and-downstream integrations better than conventional systems due to their native programmable nature. The chief concern is always the input\/output conveyors, warehouse management systems and ERP software. Conventional palletizers may require more customization and integration efforts to achieve similar levels of automation and connectivity. However, both types of palletizers are relatively easy to integrate.<\/p>\n<h4>Versatility and flexible operations<\/h4>\n<p>Robotic systems handle more types of loads and mixed-unit pallets than conventional palletizers. They palletize multiple products simultaneously, can be outfitted with various effectors and grippers, and handle empty pallets and sheets easily. Conventional systems handle one load at a time, but can handle more of it than a robotic palletizer.<\/p>\n<h4>Maintenance, training and costs<\/h4>\n<p>Both types of palletizers are relatively low maintenance, but robotic systems require slightly less work than layer palletizers. Robotic palletizers may require more specialized maintenance for robotic arms and controllers, while conventional palletizers may require more routine mechanical maintenance.<\/p>\n<p>Both systems require investment &#8211; of time, money and effort, but both offer tremendous ROI if correctly implemented. Conventional palletizer costs are usually driven by speed &#8211; the faster it is, the more it costs. Robotic system costs are driven by the versatility and effector\/gripper strategy.<\/p>\n<blockquote><p><em>The balance between operational flexibility and speed is frequently the decision point when specifying a palletizer. Once your throughput needs, manual labor requirements and load profiles are understood, this decision comes into sharp focus. Robotic systems are more versatile, but cannot match the speed or volume of layer palletizers<\/em><\/p><\/blockquote>\n<hr \/>\n<h3>Conventional palletizers: speed and consistency<\/h3>\n<p><img decoding=\"async\" style=\"width: 100%; max-width: 700px; height: auto; margin-bottom: 2px;\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/04\/conventional-palletizers.jpg\" alt=\"conventional palletizers: bag and carton palletizing\" \/><\/p>\n<blockquote><p><em>Above: carton and bag style conventional layer-type palletizers<\/em><\/p><\/blockquote>\n<p><a href=\"https:\/\/www.cisco-eagle.com\/category\/10674\/conventional-layer-palletizing-solutions\">Conventional palletizers<\/a> cover a lot of ground: they are designed for a variety of loads and a variety of situations. They can be compact, high-speed, low profile, top-layer or any number of other configurations. They can palletize bags, boxes, trays, bales, components and virtually anything else. Conventional systems are a reliable and proven technology, implemented across every industry for decades.<\/p>\n<p><strong>These palletizers work in layers<\/strong>. This means that the load is formed into a single layer, which is then stacked over by the next until the pallet is completed.<\/p>\n<h4>How do conventional systems work?<\/h4>\n<ul>\n<li>Conveyors feed conventional palletizers, either at a high or low level.<\/li>\n<li>Low-level palletizers feed a pallet at a lower elevation, often close to the floor. Low-level systems receive their products at about 3 feet from the floor.<\/li>\n<li>High-level palletizers build layers from as high as eight feet from the floor. They are typically faster than lower-level systems.<\/li>\n<li>Typical layer\/conventional systems include a pallet dispenser, transfer mechanisms, infeed\/takeaway conveyors, case-turning devices, hoists, layer-forming platforms and slip sheet dispensers. They are wired for <a href=\"https:\/\/www.cisco-eagle.com\/vector\/169\/control-systems\">automation controls<\/a>.<\/li>\n<\/ul>\n<hr \/>\n<h3>Automated robotic systems: versatility and SKU variation<\/h3>\n<p><img decoding=\"async\" style=\"width: 100%; max-width: 700px; height: auto; margin-bottom: 2px;\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/04\/robotic-palletizer-systems.jpg\" alt=\"robotic palletizer systems\" \/><\/p>\n<p><a href=\"https:\/\/www.cisco-eagle.com\/category\/10673\/robotic-palletizing-solutions\">Robotic systems<\/a> use an arm and end effector to lift and manipulate loads from a conveyor or other transport system. These systems can build pallets one SKU at\u00a0 time, or by layer depending on the load, infeed systems and required speeds. Due to their advanced vision systems, they can build a very standardized stack of bags, cartons or other loads. A lot of this functionality depends on their end effectors and tooling.<\/p>\n<h4>What comprises a robotic system?<\/h4>\n<ul>\n<li>Conveyors: <a href=\"https:\/\/www.cisco-eagle.com\/category\/972\/conveyors\">conveyors<\/a> deliver units to the palletizer, and often <a href=\"https:\/\/www.cisco-eagle.com\/category\/9115\/pallet-conveyor\">convey finished pallets away<\/a>. Sometimes, pallets are taken away by forklift or AGV, but they can often be sent downstream to a stretchwrapper or other production step.<\/li>\n<li>A robotic arm system that removes units from conveyors, then palletizes them. The type of arm depends on the weight of the loads and the speed necessary.<\/li>\n<li>An end effector. The type depends on the SKU profile; is it a bag? A case? A tray? This is sometimes referred to as end-of-arm tooling, and it can grasp everything from one heavy bag of dog food to an entire layer of heavy cases. Effector types include bundle\/clamp grippers, finger grippers, fork grippers, magnetic systems, layer grabbers, pail grippers, ring grippers or pallet\/slipsheet grippers. The effector you use is one of the most critical design decision points.<\/li>\n<\/ul>\n<hr \/>\n<h3>The role of cobot palletizers<\/h3>\n<p><iframe loading=\"lazy\" src=\"https:\/\/www.cisco-eagle.com\/video\/frame.aspx?id=964\" width=\"640\" height=\"360\" frameborder=\"0\" scrolling=\"no\"><span data-mce-type=\"bookmark\" style=\"display: inline-block; width: 0px; overflow: hidden; line-height: 0;\" class=\"mce_SELRES_start\">\ufeff<\/span><\/iframe><br \/>\n<a href=\"https:\/\/www.cisco-eagle.com\/category\/10467\/robotic-palletizing-solutions-robotiq\">Cobot palletizers<\/a> are a newer entry to the market, and can be an excellent solution for certain applications: typically, slower, lower volume operations with lighter loads and more space constraints.<\/p>\n<blockquote><p><em>We cover cobot palletizer options in this post: <a href=\"https:\/\/www.cisco-eagle.com\/blog\/2022\/07\/07\/automated-palletizing-options-finding-a-happy-medium\/\">Automated Palletizing Options: Finding a Happy Medium<\/a><\/em><\/p><\/blockquote>\n<hr \/>\n<h3>It&#8217;s all about your needs<\/h3>\n<p>Ultimately, the choice between robotic and conventional palletizers depends on factors such as production volume, product variability, space constraints, budget, and long-term operational goals. These are issues that require a full evaluation and careful consideration in advance.<\/p>\n<h4>More resources<\/h4>\n<ul>\n<li><a href=\"https:\/\/www.cisco-eagle.com\/blog\/2023\/04\/13\/targeted-warehouse-automation-manual-pallet-handling\/\">Targeted Warehouse Automation: Manual Pallet Handling<\/a><\/li>\n<li><a href=\"https:\/\/www.cisco-eagle.com\/blog\/2023\/12\/05\/roi-for-warehouse-and-manufacturing-automation-a-panel-discussion\/\">ROI for Warehouse and Manufacturing Automation: A Panel Discussion<\/a><\/li>\n<li><a href=\"https:\/\/www.cisco-eagle.com\/blog\/2023\/10\/10\/automation-starting-with-a-clean-slate\/\">Automation: Starting with a Clean Slate<\/a><\/li>\n<\/ul>\n","protected":false},"excerpt":{"rendered":"<p>Automated palletizing is fast, reliable and safe. It&#8217;s one of the priority spots for plant automation. Does robotic or conventional technology fir your needs? <\/p>\n","protected":false},"author":2,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[7],"tags":[721,315],"series":[],"class_list":["post-30186","post","type-post","status-publish","format-standard","hentry","category-automation","tag-palletizers","tag-safety-ergonomics"],"acf":[],"aioseo_notices":[],"publishpress_future_action":{"enabled":false,"date":"2027-04-21 05:36:05","action":"change-status","newStatus":"draft","terms":[],"taxonomy":"category","extraData":[]},"publishpress_future_workflow_manual_trigger":{"enabledWorkflows":[]},"_links":{"self":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/30186","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/comments?post=30186"}],"version-history":[{"count":44,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/30186\/revisions"}],"predecessor-version":[{"id":32648,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/30186\/revisions\/32648"}],"wp:attachment":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/media?parent=30186"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/categories?post=30186"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/tags?post=30186"},{"taxonomy":"series","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/series?post=30186"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}