When does palletising automation actually make sense?
Most palletising automation decisions come down to two factors:
- Throughput – how many pallets you need per hour
- Operational complexity – how consistent your product and line setup are
Low-volume, predictable operations may not justify automation at all.
Higher-volume or more complex environments often require a more capable system than teams initially expect.
The difficulty is knowing where your operation sits – and what type of system that actually points to.
This tool is designed to give you a clear starting point based on how palletising systems are specified in real-world projects.
Section 1 — Throughput
Section 2 — Product
Section 3 — Infeed
How are products fed to the palletising point?
How do you decide between manual, cobot, and robot palletising?
Most palletising decisions come down to a combination of throughput and operational complexity. Looking at just one of these in isolation often leads to the wrong system choice.
1. Throughput (pallets per hour)
Throughput is usually the starting point:
- Under ~10–12 pallets/hour
Often too low to justify full automation unless labour costs are high - 10–25 pallets/hour
Typically where cobot palletising systems are most effective - 25+ pallets/hour
Usually requires a traditional industrial robot palletiser to maintain performance
Higher throughput demands greater speed, reliability, and system robustness.
2. Product type and consistency
Not all products behave the same in a palletising system. Key factors include:
- Product type (cartons, cases, bags, trays)
- Weight per pick
- Number of SKUs
- Consistency in size and shape
Consistent cartons on a single SKU are straightforward.
Mixed products, bags, or variable dimensions increase complexity and may require more advanced systems.
3. Infeed and line setup
How products arrive at the palletising point can significantly affect system design:
- Single conveyor with consistent orientation → simplest setup
- Mixed orientation or manual loading → more complex
- Multiple infeed lines → requires coordination and buffering
Even moderate throughput operations can become complex if the infeed is inconsistent.
This tool combines all of these factors to give a realistic recommendation — not just a basic throughput estimate.
What’s the difference between cobot and robot palletising systems?
The choice between a cobot and a traditional robot depends on speed, payload, and how complex your operation is.
Read our guide for a full breakdown on the differences between a Cobot Palletiser vs Robotic Palletiser.
Cobot palletising systems
Cobot palletisers are designed for simplicity and flexibility.
They are typically suited to:
- Lower to mid-range throughput
- Consistent product types
- Limited floor space
- Faster deployment requirements
Advantages:
- Lower upfront cost
- Quicker installation
- Often no safety fencing required
Limitations:
- Lower speed compared to industrial robots
- Payload restrictions
- Less suited to complex or highly variable operations
Traditional robot palletising systems
Industrial robot palletisers are designed for performance and scalability.
They are typically used when:
- Throughput is high
- Products are heavy or unstable
- Multiple SKUs or formats are involved
- Several infeed lines need to be managed
Advantages:
- Higher speed and throughput
- Greater flexibility for complex applications
- Better suited to long-term scaling
Considerations:
- Higher upfront cost
- Requires safety guarding
- More integration work
When automation may not be the right step
Automation isn’t always the answer.
It may not be justified if:
- Volumes are very low
- Product variability is high
- Processes upstream are inconsistent
- Labour cost pressure is minimal
In these cases, manual or semi-automated solutions may be more appropriate for now.
How much does palletising automation cost in the UK?
Costs vary depending on throughput, product type, and complexity, but typical ranges are:
- Cobot palletising systems: £40,000 – £120,000
- Traditional robot palletising systems: £150,000 – £500,000+
Additional costs may include:
- Integration and commissioning
- End-of-arm tooling (grippers)
- Conveyors or line modifications
- Ongoing maintenance and support
Because costs vary significantly by application, it’s best to treat these as indicative ranges rather than fixed prices.
Tip:
Use the ROI calculator to estimate payback based on your specific operation before speaking to suppliers.
What should you do after getting your result?
Your next step depends on the recommendation you receive.
If you’re a cobot palletising candidate
Start by building a financial case:
- Estimate labour savings
- Calculate payback period
- Understand total cost of ownership
This will make supplier conversations far more productive.
If you’re suited to a traditional robot
You’ll likely need a more detailed assessment:
- Engage with experienced integrators
- Review layout and line integration
- Define throughput and performance requirements
If you’re borderline or not ready
Focus on what would change the outcome:
- Increased throughput
- Improved product consistency
- Simplified line setup
Automation may become viable as your operation evolves.
Frequently asked questions
What is the minimum throughput for palletising automation?
Most projects begin to make sense from around 10–15 pallets per hour, but this depends on labour costs and consistency.
Can a cobot palletiser handle multiple SKUs?
Yes, but high SKU variation increases complexity and may reduce efficiency.
Can cobots handle bags or irregular products?
In some cases, but these applications often require specialist grippers and may be better suited to traditional robotic systems.
Do palletising systems require safety fencing?
Traditional robots typically require guarding. Cobot systems may not, depending on the application and risk assessment.
How long does installation take?
Cobot systems can often be installed within a few months. Larger robotic systems may take longer depending on complexity.
What happens if product sizes vary?
Variation increases system complexity and may require more advanced sensing, programming, or handling solutions.