Robotic Palletizing


Fast, Flexible & Reliable Robotic Palletizing Systems for Any Application

With rising costs of labor, a need for safe working environments, and maintaining operations with the latest cutting-edge technology, a robotic palletizing system is a smart option to increase accuracy, reliability and efficiency. Robotic palletizers are highly customizable to suit a variety of product types and applications, as well as multiple infeed and discharge layouts to fit your requirements.

Proper development, engineering, integration, and after-market service are invaluable for the overall success of a system integration project throughout its life cycle. With the ability to provide highly customized strategies, implement advanced technologies, and take a consultative approach to working together, Bastian Solutions is your partner for palletizing solutions. 

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How Robotic Palletizing Works

molnlycke_pharma_distribution_center_robotic_palletizingProducts to be palletized are fed into the robotic cell via the infeed conveyor system. A pallet is deposited into the pallet loading area either by an automated pallet dispenser or by the palletizing robot. The robot picks one or multiple products at a time, then quickly and accurately places them on a pallet.

The pattern is constructed layer by layer, utilizing slip or tier sheets if needed. Once the load is complete, the pallet is removed from the robotic cell via the outfeed conveyor for stretch wrapping or other downstream processing. The palletizing robot repeats the process with a new pallet.

Robotic palletizing systems can be designed to palletize a wide range of products:

  • Standard applications: cases, mixed pallets, or bags
  • Unique, custom needs: scrap metal bails, batteries, and other heavy, hazardous materials.

Pallet Pattern Software
StackOrder™, our proprietary pallet pattern editor software, allows customers to visualize and edit pallet stacking patterns used by their Bastian Solutions’ palletizing robots. Users can implement and manage patterns across the entire fleet using our pattern selector software, StackOrder GO™. These applications improve speed and accuracy of current palletizing processes and can adapt to future operational needs.

End of Arm Tooling
Custom-designed EoATs (end of arm tools) expand the robot’s capabilities beyond just stacking products, allowing it to also handle pallets, slip sheets and tier sheets, fully automating the palletizing process without adding additional equipment. Custom EoATs can also be designed for difficult-to-handle, delicate, or hazardous products.


Case, Row and Full Layer Palletizing – Robots can be used to palletize a multitude of different cases, consisting of different shapes, sizes, weights, and materials including corrugated boxes, plastic cartons, and aluminum or metal cartons. Rainbow pallets can also be created; they comprise of a single SKU per layer with multiple SKUs per load. 

Bag Palletizing – When palletizing bags, optional equipment for checkweighing, bag flattening, bag labeling, or bag squaring can be integrated prior to the palletizing cell to reduce order inaccuracies and increase load stability. Typically, end of arm tools with "clam" style grippers are used to pick up the bags without punctures. An interlocking stacking pattern and tier sheets can be applied to the load to increase load stability.

Custom Palletizing Solutions – Our engineers have designed and built custom robotic palletizing solutions for a variety of challenging applications, including harsh environments like refrigerated warehouses and difficult-to-handle, heavy and hazardous products like scrap metal and batteries. With the installation of these custom systems, our clients reduced many of the operational hazards facing their workforce.


Features & Benefits

  • High system reliability and superior up-time increases overall throughput
  • Improves ergonomic conditions and reduces operating costs by handling heavy lifting and repetitive movements
  • Seamless integration is flexible and scalable with business growth
  • Interfaces with upstream and downstream equipment for fully automated operations
  • Increase the density, stability, and accuracy of pallet loads with proprietary StackOrder™ and StackOrder GO™ pallet pattern software
  • Precise and safe handling for an array of products including cases, totes, bags, trays, tier sheets, buckets, bins, batteries, and oddly shaped or heavy items


When thinking about a robotic palletizing solution for your operations, it’s important to consider the following factors:

  • Labor availability and costs
  • Product size, shape, weight and packaging
  • Number of infeed and outfeed lines - 1 in / 1 out, 2 in / 2 out, or custom
  • Facility layout and available footprint
  • Robotic reach, payload, speed
  • Item manipulation to identify number of robotic axes; standard 4-axis or 5- or 6- axis robots if items need to be tilted or rotated
  • Throughput rates to determine number of robots
  • Pallet stacking pattern variety and complexity
  • Factory acceptance testing (FAT) ensures our solutions meets your standards

Technology & Specifications

Robotic palletizing systems typically consist of the following technologies:

Depending on your needs, this equipment can be purchased from our vendor partners or designed and manufactured by Bastian Solutions. For enhanced capabilities, the following technologies can also be included:

  • 3D or AI-powered vision system
  • Foundry-grade options
  • Enhanced safety software
  • Robot on rail systems for increased infeeds

See More Solutions


Robotic Integration Services


McCormick Case Study


Mölnlycke Case Study


Robotics Capabilities Brochure

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