Palletizer

Palletizer

A palletizer is a machine that automatically sorts, transfers, stacks, and secures packaged goods onto pallets, providing fast automated preparation of products for shipping. Positioned at the end of production lines, palletizers replace manual labor with precision and speed that only mechanized and computerized systems can deliver.

Palletizing equipment handles products at high-level or floor-level elevations using conventional or robotic systems, accommodating various product types including cases, crates, trays, bundles, and bags.

Types of Palletizers

Three main categories of palletizers exist, each with distinct operating principles and advantages:

Robotic Palletizers

Robotic palletizers use a hydraulic robotic arm to pick products from conveyor lines and place them onto pallets in organized patterns. These systems offer maximum flexibility for diverse applications.

Advantages:

• Smaller footprint than conventional palletizers
• Flexibility in handling different product types and stacking patterns
• Capability to service multiple production lines and pallets simultaneously
• Lift capacity up to 1,000 kg
• Potential for mixed load handling on single pallets
• End-of-arm tools (end effectors) adaptable to various configurations and packaging types

Considerations:

• Generally higher cost than conventional systems
• Lower speed compared to high-level conventional palletizers

Low-Level Palletizers

Low-level palletizers load products from ground level (0.76–0.91 m operating height), using conveyors to transfer and sort items onto pallets continuously.

Advantages:

• Lower cost than robotic systems — less complex construction
• Easier maintenance and operation
• Capacity up to 15 cases/minute
• Creates compact, stable pallets
• Handles cases, bags, crates, bundles

High-Level Palletizers

High-level palletizers load products from elevated positions (2.13–3.15 m), offering the highest throughput for demanding production environments.

Advantages:

• Capacity up to 200 cases/minute
• Fastest palletizing method for high-volume operations
• Creates very compact pallets
• Handles cases, bags, crates, bundles, trays

Palletizer Comparison

Mixed Case Palletizing

Mixed case palletizing addresses the challenge of stacking boxes of varying sizes efficiently on minimal pallets — a practical application of the three-dimensional bin packing problem. This technique optimizes space utilization in logistics operations.

Modern developments include Deep Reinforcement Learning systems that train robotic agents to determine optimal box placements through simulated palletizing scenarios, with some models successfully deployed in real-world environments.

Palletizer Technology Evolution

Palletizing technology has evolved significantly since the first mechanized palletizer was developed by Lamson Corp. in 1948:

• 1950s — Row formation palletizers introduced; loads organized in dedicated areas before layer transfer
• 1970s — Inline palletizers developed for faster speeds using continuous flow dividers
• 1980s — Robotic palletizers with end-of-arm tools (end effectors) for flexible product handling
• Recent years — Enhanced end effectors adapting to various configurations and packaging types

Leading Palletizer Manufacturers

The market features established brands with proven reliability:

Used palletizers from these manufacturers offer proven technology with available spare parts and service support worldwide.