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A palletizer is a mechanical system that automatically stacks and organizes products into a single, stable unit load for easier handling, warehousing, and shipping. Palletizers are widely used at the end of a packaging line to move cartons, cases, bags, trays, bundles, or shrink-wrapped products from production into shipment-ready pallet loads. In many facilities, palletizing is integrated with upstream and downstream packaging equipment such as checkweighers, counters, sorters, labeling and coding systems, metal detection, stretch wrapping, and pallet handling conveyors.
Palletized loads improve material flow because it is faster and more cost-effective to transport one consolidated unit than to move many individual items. Finished goods are typically packed into boxes, cases, trays, or crates before they enter the palletizing process, creating a consistent secondary package that can be stacked in a repeatable pattern. Once these packages are arranged onto a pallet or placed into roll cages, they become a unit load that is easier to track, protect from damage, and stage for distribution. Roll cages are often categorized as tertiary unit loads because they support and secure multiple packaged items for internal movement and shipment.
The palletizer places products onto a pallet in a defined stacking pattern designed for stability, cube utilization, and safe transport. Pallets are flat, load-bearing platforms made from materials such as wood, plastic, paper, or metal, and they feature openings that allow forklifts and pallet jacks to lift and move the load. These openings classify pallets as two-way or four-way entry based on the directions equipment can access them. Most standard pallets can support loads approaching one metric ton over an area close to one square meter, though capacity depends on pallet design, material type, and how the load is distributed across the deck.
| Dimensions (W x L) in millimeters |
Dimensions (W x L) in inches |
Unused Floor Space (ISO Container) |
Region |
| 1016 x 1219 | 40.0 x 48.00 | 3.7% | North America |
| 1000 x 1200 | 39.37 x 47.24 | 6.7% | Europe, Asia |
| 1165 x 1165 | 45.9 x 45.9 | 8.1% | Australia |
| 1067 x 1067 | 42.00 x 42.00 | 11.5% | North America, Europe, Asia |
| 1100 x 1100 | 43.30 x 43.30 | 14% | Asia |
| 800 x 1200 | 31.50 x 47.24 | 15.2% | Europe |
Some palletizers are designed to stack products using slip sheets or directly onto conveyor surfaces rather than traditional pallets. These systems are commonly referred to as unitizers. Unitized loads eliminate the need for pallets altogether, which can reduce material costs, improve hygiene, and increase trailer and container utilization. In certain industrial contexts, the terms “palletizer” and “unitizer” are used interchangeably, particularly when the system’s primary function is to consolidate products into stable unit loads rather than place them on wooden or plastic pallets.
There are three primary pallet types manufactured from wood or plastic, along with one widely used option made from corrugated cardboard.
The most common pallet in North America is the GMA pallet, which typically measures 40 × 48 inches. It features notches along the stringers that allow side entry by forklifts and pallet jacks, making it well suited for standard material handling operations.
The CHEP pallet is the second most widely used design. It is also commonly sized at 40 × 48 inches but uses a block-style construction that allows four-way entry from all sides. These pallets are easily identified by their blue color and are frequently used in closed-loop and pooled pallet systems.
PECO pallets are another growing option in the pallet industry, offering similar functionality to CHEP pallets. They are typically identified by their red paint and are also used in pallet pooling programs that emphasize durability, consistency, and reusability.
The pull board is constructed from corrugated material and includes two three-inch tabs, usually positioned on adjacent sides. Forklifts equipped with specialized push-pull attachments use these tabs to move loads on and off the forks. Pull boards are valued for their hygienic properties and space efficiency, as they can reduce pallet height and free up as much as five additional inches per load. This height reduction can allow more product layers per truckload, generating significant transportation and warehousing cost savings.
Certain palletizers are engineered to stack products on slip sheets or conveyor surfaces, creating what are known as unitized loads. In these applications, pallets are not required, and the distinction between palletizers and unitizers becomes less pronounced.
Different industries and distribution networks often require customized pallet configurations to meet specific handling, stability, and transportation requirements.
Pallet patterns are engineered stacking arrangements designed to maximize load stability, strength, and space efficiency. A common approach uses a column-stacked base that aligns box corners vertically, creating a strong foundation capable of supporting stacked loads. In warehouse environments, pallets may be stacked up to four units high, relying on this vertical alignment to distribute weight evenly.
Interlocked layers are often added at the top of the load to improve resistance to shifting and tipping. This combination of column stacking and interlocking allows unwrapped or lightly wrapped loads to be safely transported by forklift from the palletizer to a stretch wrapping or securing station without compromising load integrity.
Before the advent of automatic palletizing systems, warehouses and distribution centers relied heavily on manual hand stacking to organize products into pallet loads for storage and shipping. This method of manual palletizing was extremely labor-intensive and time-consuming, with workers expending considerable physical effort to achieve relatively low throughput. As global commerce expanded and supply chain efficiency became a top priority, the need for optimized material handling solutions became increasingly apparent. The adoption of pallets and pallet handling equipment revolutionized logistics in the early 20th century, particularly during World War II, when rapid and reliable transport of heavy loads became critical for military and industrial supply chains.
The introduction of the first mechanical palletizer by Lamson Corp. in 1948 marked a major milestone in warehouse automation technology. This early row-forming palletizer was designed to automate the process of arranging products—such as cases, cartons, bags, or boxes—into rows. These rows were then systematically transferred to a stacking area, where each new layer was placed upon the previous one until a complete pallet load was constructed. Compared to manual operations, this innovation greatly increased both throughput and consistency, setting the stage for future advancements in automated palletizing equipment and machinery.
With the rise of high-speed production and distribution demands in the 1970s, the material handling industry introduced the in-line palletizer. Unlike traditional row-forming palletizers that relied on intermittent movement, in-line palletizers utilized continuous product flow technology. This enabled the precise orientation and positioning of products onto layer-forming platforms, significantly boosting line efficiency and reducing bottlenecks. In-line palletizers are especially valued in industries such as food and beverage, consumer packaged goods, and manufacturing, where rapid end-of-line automation is essential for scalable operations.
The 1980s brought further innovation with the development of robotic palletizers, a major leap forward in automation and versatility. These advanced palletizing robots employ articulating arms equipped with end-of-arm tooling (EOAT)—such as mechanical grippers, vacuum suction grippers, or magnetic devices—tailored to handle a diverse array of packaging types and product sizes. Robotic palletizing systems facilitate flexible operation, fast changeovers, and precise stacking patterns, making them ideal for environments with high product variability or custom palletizing requirements. The widespread adoption of robotic and automated palletizing solutions has since transformed modern warehouses, distribution centers, and manufacturing facilities, leading to greater productivity, improved worker safety, and enhanced supply chain optimization.
Today, the evolution of palletizer technology continues with the integration of smart sensors, machine learning algorithms, and cloud-based warehouse management systems. Advanced automatic palletizers and robotic palletizing solutions now offer real-time data tracking, predictive maintenance, and seamless connectivity with upstream and downstream automation for enhanced operational efficiency. As e-commerce, just-in-time delivery, and global trade accelerate, investing in state-of-the-art palletizing systems is increasingly essential for businesses aiming to minimize costs, reduce manual labor, and stay competitive in the rapidly evolving materials handling industry.
Palletizers—core automation assets in material handling and end-of-line packaging—are commonly classified into two primary categories: conventional palletizers and robotic palletizers. Both are designed to receive products, orient them, and stack them into stable pallet loads at either high- or low-elevation infeed points. High-level infeeds typically range from 84" to 124", while low-level infeeds are usually between 30" and 36". Within the conventional category, two dominant configurations are used: floor-level (low-level) palletizers and high-level palletizers. Understanding how each operates—and where each excels—helps manufacturers optimize throughput, floor space, and long-term automation ROI.
Floor-level palletizers, also referred to as low-level palletizers, operate with an infeed conveyor height of approximately 30" to 36". Products such as cases, cartons, bags, or shrink-wrapped bundles move along the infeed conveyor and pass through a turning device or orienting conveyor to ensure proper alignment. From there, items enter a row-forming zone where they are arranged into uniform rows. Completed rows are transferred to a layer-forming area, where a full layer is assembled and positioned for placement.
Once a layer is complete, it advances to a stripper plate that accurately positions the layer onto the pallet or the previously stacked layer. Throughout this process, the pallet remains stationary, which enhances load stability and reduces the risk of product damage. After the pallet reaches its programmed height or layer count, it is discharged—typically at an 18" conveyor height—for downstream handling such as stretch wrapping or transport.
Floor-level palletizers are often selected for their lower capital cost, compact footprint, and simplified mechanical design compared to high-level systems. Because major components are accessible at ground level, preventive maintenance and troubleshooting are faster and safer. Operators can easily monitor pallet formation and make adjustments without elevated platforms. These systems integrate smoothly with other packaging equipment—such as case erectors, packers, sealers, and stretch wrappers—since they avoid complex elevation changes. As a result, floor-level palletizers are well suited for low- to moderate-speed applications where space efficiency, ease of maintenance, and cost control are priorities.
High-level palletizers are designed for high-speed, high-throughput palletizing environments and typically feature infeed conveyor elevations between 84" and 124" or higher. Similar to floor-level designs, products travel along the infeed conveyor to an orienting mechanism before entering the row-forming section. There, products are grouped into rows and transferred to a layer-forming platform that assembles complete layers with precise positioning.
Unlike floor-level systems, high-level palletizers usually incorporate a stack-lifting or lowering mechanism that adjusts pallet height as each new layer is added. Once palletizing is complete, the finished load is lowered to a discharge conveyor—generally positioned between 18" and 30"—where it proceeds to stretch wrapping, labeling, or forklift pickup. Elevated operator platforms are commonly included to provide clear visibility and ergonomic access for monitoring high-speed operations.
High-level palletizers are preferred in facilities with sufficient ceiling clearance and where maximum throughput is required. They are capable of handling demanding production rates—often 40 to 50 units per minute or more—regardless of upstream equipment discharge height. This makes them ideal for beverage bottling, food processing, consumer packaged goods, and large-scale distribution centers. Their design supports precise pallet patterns, continuous operation, and scalable performance, delivering strong ROI for operations planning future growth or frequent product changeovers.
When selecting between floor-level and high-level conventional palletizers, key considerations include product size and weight, required palletizing speed, available floor and overhead space, integration with existing automation such as conveyors and stretch wrappers, maintenance accessibility, energy consumption, and total cost of ownership. Working with an experienced palletizer manufacturer or packaging automation specialist can help ensure the chosen system aligns with operational goals—whether that means minimizing upfront investment with a floor-level palletizer or maximizing speed and scalability with a high-level solution.
A palletizer is a mechanical system that stacks and organizes products into unit loads on pallets. This streamlines product handling, storage, and transportation as part of automated packaging operations.
Floor-level palletizers have low infeed conveyors (30"–36"), are compact and easy to maintain, while high-level palletizers use elevated infeed conveyors (84"–124") for high-speed, high-volume operations, often in manufacturing and distribution centers.
Common pallet types include GMA, CHEP (blue), PECO (red), and Pull Board pallets, each with different construction and handling features to suit various industrial applications.
Palletizing began with manual stacking, advanced to mechanical palletizers in 1948, then in-line palletizers in the 1970s, and robotic systems in the 1980s, now integrating smart sensors and machine learning in modern automated solutions.
In North America, common pallet sizes are 1016x1219 mm (40x48 in) and 1067x1067 mm (42x42 in). Europe uses 800x1200 mm (31.5x47.24 in) and 1000x1200 mm (39.37x47.24 in). Asia utilizes 1100x1100 mm (43.3x43.3 in).
Unitizers stack products into unit loads using slip sheets or conveyor surfaces instead of pallets. The terms "palletizers" and "unitizers" are sometimes used interchangeably, especially when no pallet is required.
A conventional palletizer consists of various components, including both static and moving parts. Some of these components may be integrated directly into the palletizer, while others can be installed as separate pieces of equipment.
Bags exiting the packaging units and sewing machines are typically in an upright position. They are then positioned or flattened by the knockdown conveyor to prepare them for palletizing.
This can be either an integrated or separate machine used to ensure the accuracy of the weights of bagged products prior to storage and distribution.
Similar to the checkweigher, this device can be integrated with the palletizer or operate as a separate machine. The metal detector identifies any ferrous, non-ferrous, or stainless-steel contaminants in the product.
Products that are detected as either being off-weight or containing metal contaminants are diverted by the reject conveyor to a staging area or platform.
Products can enter a palletizer from different sides, including the side, rear, or front. These infeed types apply to both floor-level and high-level palletizers.
To ensure the pattern is formed correctly, the bag flattener adjusts and shapes the bags to the proper height.
As products are fed onto the palletizing machine via the conveyor, they are oriented into the correct position before entering the row-forming area. Various turning devices are used for this purpose, including turn shoes, cushioned turns, turntables, and soft turn devices. Turn shoes and cushioned turns gently nudge the product to rotate it by 90°. Turntables lift and rotate products by +90°, -90°, or 180°. Soft turn devices utilize two sets of rollers driven by variable frequency drives (VFDs) to achieve rotations of +90°, -90°, or 180° by varying roller speeds.
These mechanical devices are used to create the desired pattern in the row-forming area by establishing side-to-side gaps. Stops are activated by pneumatic valves and cylinders, which are controlled by programmable logic controllers (PLCs). To alter forming patterns, only software controls need to be adjusted, eliminating the need for hardware changes.
These mechanical devices, similar to stops, assist in pattern formation by creating front and back gaps. Once a layer is complete, it is transferred onto a stripper plate or apron, which then moves it onto the pallet. When the stripper plate is in place on top of the pallet or stack, a gate descends to block the layer's movement. The stripper plate is then retracted, leaving the layer in position on the stack. A pusher gate holds the layer in place until it is released.
This component enables the creation of front and back gaps without the need for a pusher gate. As the stripper apron opens in the middle, it forms gaps while the layer is placed onto the stack below.
As the name suggests, this component dispenses and conveys pallets to ensure the continuous operation of the palletizer. When one unit load is completed, the pallet dispenser feeds a new pallet. Typically, a pallet dispenser holds 10 to 20 pallets in its pallet magazine.
For some materials, such as bagged products, slip sheets are needed between layers. A slip sheet dispenser uses a venturi vacuum system to efficiently place these slip sheets.
This component transfers completed unit loads onto a platform, where they can be picked up by forklifts or hand pallet trucks for storage.
This is the control area where operators troubleshoot, adjust, or reprogram the palletizer and its automated components. The main element of the control panel is the PLC, which controls circuit functions according to the machine’s programming.
Robotic palletizers use programmable robotic arms equipped with specialized end-of-arm tooling to pick, orient, and stack products into precise pallet patterns. Unlike conventional palletizers, robotic palletizing systems offer greater flexibility, adaptability, and precision, making them ideal for facilities that handle multiple product types, frequent changeovers, or complex stacking configurations. Based on mechanical design and range of motion, robotic palletizers are commonly classified as Cartesian, gantry, SCARA, and articulated palletizers, with each type offering distinct advantages in speed, payload capacity, and workspace coverage.
Cartesian palletizers operate using linear motion along three perpendicular axes—X, Y, and Z—hence their name. The robotic end-of-arm tool is mounted to a rigid mechanical structure composed of beams and a telescopic vertical mast, typically driven by precision-controlled servo motors. Movement is highly accurate and repeatable, making Cartesian palletizers well suited for applications involving uniform products with consistent dimensions and weights.
While Cartesian palletizers generally operate at slower speeds compared to other robotic types, they are among the most cost-effective robotic palletizing solutions available. They are commonly used for single-line palletizing applications with speeds of up to approximately 10 items per minute. Their simple design, predictable motion paths, and lower upfront cost make them a practical choice for manufacturers transitioning from manual palletizing to basic automation.
Gantry palletizers feature an end effector mounted on a horizontal beam that travels along one axis, while the beam itself moves along a perpendicular axis, enabling motion across the X-Y plane. Vertical movement along the Z-axis is achieved through a telescoping or articulated lifting mechanism. Due to their linear motion characteristics, gantry palletizers are often considered a subset of Cartesian robotic systems.
Compared to standard Cartesian palletizers, gantry palletizers are typically larger, more robust, and capable of handling heavier payloads. Although they may operate at slower speeds and involve higher installation costs, their structural strength makes them ideal for palletizing large, heavy, or bulky products such as bags, building materials, or industrial components. Gantry palletizers are commonly deployed in high-load applications where lifting capacity and reach are more critical than cycle speed.
SCARA palletizers are designed with selective compliance in the horizontal plane and rigidity in the vertical axis. This configuration allows the robotic arm to move rapidly left, right, forward, and backward while maintaining precise vertical positioning. The articulated arm structure resembles a human arm, consisting of two linked segments joined by rotational joints that enable folding and extension.
SCARA palletizers offer significantly faster cycle times than Cartesian systems and are capable of servicing multiple palletizing lines from a single installation. Typical operating speeds reach approximately 20 items per minute, making SCARA robots well suited for medium-speed packaging lines requiring moderate flexibility. Their compact footprint and high repeatability make them popular in food processing, consumer goods, and pharmaceutical palletizing applications.
Articulated palletizers provide the highest level of flexibility among robotic palletizing systems. Unlike SCARA robots, articulated palletizers feature multiple rotary joints and additional degrees of freedom, typically ranging from four to six axes of motion. One arm segment is mounted on a fixed base with a swivel joint, allowing the robot to reach around obstacles, service multiple pallet positions, and accommodate complex pallet patterns.
These robotic palletizers are faster than SCARA systems and can handle multiple production lines simultaneously, with typical operating speeds of 25 items per minute or more. Articulated palletizers are widely used in high-mix, high-throughput environments where product sizes, weights, and pallet configurations vary frequently. Their versatility, speed, and scalability make them a preferred choice for advanced automated packaging lines in industries such as food and beverage, logistics, and fast-moving consumer goods.
Robotic palletizers vary in their approach to pattern formation and use distinct components based on their design. While elements such as check weighers and metal detectors are utilized, they are typically installed as separate pieces of equipment. Below are the common components of a robotic palletizer.
This component supports the end effector and allows linear movement along a single axis. Motion is provided by servo motors through mechanisms such as rollers and rails, rack and pinion gearing systems, or chain and sprocket drives. Beams are commonly found in Cartesian and gantry palletizers.
Mounted on a fixed base, this part supports the beam or arm and end effector assembly. It uses hydraulics, servo motors, or chain drives to enable vertical movement, allowing the connected components to move up and down.
Typically consisting of two linked segments, arms enable the end effector to move horizontally by rotating, extending, or folding.
These components provide rotational movement between various parts of the palletizer system. The number of joints can vary depending on the required versatility of the system.
Often referred to as end-of-arm tools, end effectors are crucial in robotic palletizer assemblies due to their versatility compared to conventional palletizers. They are responsible for picking up and placing products in the correct location and orientation on the stack. Designed to handle a variety of products with a single tool, they can also be equipped to retrieve pallets from a pallet rack or to pick slip sheets, tier sheets, or top caps from a dispensing rack. These features enhance the robot's functionality and efficiency.
Following are the most common types of end effectors.
Clamps lift products by gripping the sides, enabling the handling of multiple items with the same orientation simultaneously, which speeds up throughput. They are particularly useful for stable products or those not suited for vacuum handling, such as HSC (cases with no top) or display cases.
Fork tools are used for delicate, unstable, or special cases like HSC (cases with no top) or warm/hot shrink-wrapped products where gentle handling is necessary. The tool features cutouts that allow it to slide underneath the product for lifting and cradling. A clamp can be added to the fork tool for added stability during movement.
Finger end effectors are mechanical tools that open and close in two directions, providing support underneath the product. They are commonly used for handling bags.
Vacuum end effectors are commonly used for picking up RSC cases and can be configured to handle multiple cases simultaneously. They use a blower to generate a high volume of vacuum necessary to lift thin, porous corrugated boxes made from recycled materials. This approach is often preferred over venturi systems, which rely on plant air that may be unreliable or insufficient for the required air volume.
Bag end-of-arm tools are designed to pick up large bags of product one at a time. They can be equipped to add slip sheets or tier sheets between layers, depending on the speed requirements.
Magnetic end effectors use electromagnets to handle products and are typically employed for stacking and palletizing canned goods.
While conventional palletizers represent the earlier generation of palletizing technology, they are not fully superseded by newer robotic models. Each type of palletizer offers distinct benefits tailored to specific applications. Given the wide variety of industries that utilize palletizers, no single design fits all needs. Below are the advantages of using conventional palletizers compared to robotic ones.
Merits of Using Conventional Palletizers:
Conventional palletizers build the unit load by turning and pushing products into their designated positions and orientations, eliminating the need to pick up and place each item. This method allows for flexibility in handling different packaging dimensions or types without affecting the palletizer's operation. Any necessary adjustments can be made through control program changes, without requiring hardware modifications.
Robotic palletizers can be slow when operating by picking and placing individual products. To improve throughput, they often collect and handle multiple products simultaneously. However, this approach typically offers less flexibility compared to conventional palletizers, which can be easily adjusted to change pattern configurations without impacting throughput.
Benefits of Robotic Palletizers:
For straightforward palletizing tasks where speed is less critical, a robotic arm can be a cost-effective choice. It eliminates the need for additional systems such as conveyors, turning mechanisms, stoppers, and gates. As long as the robotic arm meets the required throughput, it presents a more economical solution.
A single robotic palletizer can be positioned between several packaging lines and handle multiple product types simultaneously. In contrast, conventional palletizers require separate upstream product accumulation systems to manage multiple lines. By eliminating the need for these additional systems, robotic palletizers reduce overall investment costs.
Robotic palletizers offer greater flexibility in changing pattern formations compared to conventional systems. However, it’s important to note that modifying the pattern may impact the palletizer's throughput.
Hybrid palletizers are advanced palletizing systems that merge the high-speed efficiency of conventional palletizers with the adaptability and intelligence of robotic palletizing technology. These systems are designed to deliver fast, reliable throughput while accommodating a wider range of products, pallet patterns, and operational requirements than traditional palletizers alone.
In a hybrid palletizing system, products are typically organized using conventional row-forming components such as turning devices, guides, and stoppers. Once a complete layer is formed, a robotic arm—rather than a mechanical lift or elevator—picks up the entire layer and precisely places it onto the pallet or stack. By handling full layers instead of individual items, hybrid palletizers maintain high production speeds comparable to high-level palletizers while significantly increasing flexibility.
This configuration eliminates one of the main limitations of high-level palletizers, which rely on inclined conveyors to elevate products to higher stacking positions. Removing the need for extensive elevation conveyors simplifies system layout, reduces mechanical complexity, and lowers maintenance demands. At the same time, the robotic layer-placement capability allows for rapid changeovers, complex pallet patterns, and improved handling of varying product sizes or packaging formats.
Hybrid palletizers are especially well suited for operations that require both high throughput and frequent pattern changes, such as food and beverage production, consumer packaged goods, and distribution centers. By blending conventional speed with robotic precision, hybrid palletizers offer a balanced solution that improves line efficiency, enhances pallet stability, and supports scalable automation strategies for modern packaging and material handling environments.
Another type of hybrid palletizer features robotic pattern forming. In this setup, a robotic arm handles the orientation and positioning of products in the layer-forming area. Once the layer is complete, a conventional palletizer takes over to place it on the stack and manage additional tasks, such as feeding pallets and slip sheets.
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