Created on 09.07

How to Choose the Right Packing Automation System for Your Production Line

As manufacturing companies strive to enhance their productivity levels, quality, and minimize the need for human labor, automated packing has gained significance in today's end-of-line production systems.

However, choosing the right automation system is not just about picking the fastest robot. Instead, the choice of the best automation system should take into account several considerations that include the type of product being packaged, the type of packaging, the volume of production, the need for flexibility, and available space, among others.

For manufacturers who are contemplating the use of robotic systems for case packing or palletizing, it is vital that they understand how the robotic solutions differ.

Techflowbot offers robotic automation systems for case packing, palletizing, and depalletizing. Its robotic packaging and end-of-line automation solutions are designed around different production requirements, helping manufacturers select systems that match their products, packaging processes, layouts, and production goals.

Begin by Defining the Task of the Packaging System

Prior to choosing a robot, manufacturers should first determine the automation system's task requirements.

Although case packing and palletizing are two distinct tasks, they belong to end-of-line automation systems.

Case packing is normally the task of filling individual products into boxes, cases, or any other secondary packaging. The automation system will have to perform product handling and packaging within a continuous flow of production.

Palletizing occurs at a later stage where products or cases are loaded on top of each other on pallets in a certain pattern.

Therefore, the choice of the robot architecture largely depends on the task being performed.

Automated Twin-Axis Casepacking Robots for Case Loading Applications

These robots have been designed specifically for the task of automated case packing applications whereby the products need to be picked and loaded into cases.

For manufacturers looking for more information about twin-axis case packing technology, Techflowbot also provides a detailed guide to dual-axis case packing robots and their role in automated case packing.

The linear movement structure makes this kind of robotic system ideal for applications whereby the products have a predictable path, and the task is efficient in nature as far as top-loading or case loading is concerned.

Techflowbot twin-axis casepacking robot for automated case packing

Efficient and Controlled Case Loading

For those products which are required to be packed in cases in a consistent manner, this kind of system is capable of providing controlled product movements and product placements.

This can prove useful in applications involving those products which need to be transferred from one conveyor to another through secondary packaging such as bags, bottles, and other packaged products.

Since this robotic system provides a relatively simple movement structure, the system will be able to provide an efficient solution to the case-packing task, which is not complicated when it comes to product orientations.

Line Space Optimization

When designing an automated production line, the factory floor space needs to be considered carefully.

Through its overhead case packing configuration, the robot is able to efficiently utilize the overhead space of the conveyor while maintaining the floor space near the production line open.

This will be quite beneficial when the manufacturer wishes to automate his production process by installing a robotic system in his existing factory without altering the whole plant layout.

When is a twin-axis system suitable?

In cases where:

There is a need to automate the case packing/loading process.
The products have a predictable conveyor path.
There is the need to have repeatable product placements.
There is not much floor space available.
There is a need for an overhead packing configuration.

However, the applications involving complex product orientation will require a completely different robotic architecture.

Collaborative Palletizing Robots for Flexible Production

Collaborative robots, or cobots, can offer a new solution for manufacturers seeking more flexibility in palletizing operations.

As opposed to traditional robot systems, collaborative robots are built with human-robot interaction in mind. In certain cases, this solution can be appealing for manufacturers requiring operator interaction with the automation equipment or those with frequently changing production needs.

Flexibility for Changing Production Needs

There are many manufacturers handling various products or packages, as well as various pallet patterns.

In such cases, flexibility can be as important as efficiency.

The solution of collaborative palletizing can be useful in environments where different products or palletization patterns are required. Such an approach is especially suitable for manufacturers dealing with numerous product variants instead of one very standardized manufacturing process.

Promoting Flexibility in Factory Layout Design

Another thing to consider is the production space.

In situations where the manufacturers want to maximize the available space or incorporate robotics in their existing production system, the collaborative palletizing system can be a good choice.

However, it must be noted that the exact safety configuration of the robot depends on many factors, including payload, speed, tooling, workspace, and the results of the required risk assessment. Collaborative robot applications should be evaluated according to the specific installation and applicable safety requirements. Manufacturers can refer to ISO 10218-2:2025 safety requirements for industrial robot applications for additional information on the safety of industrial robot applications and robot cells.

When Can a Collaborative Palletizing Robot Be Recommended?

In cases where:

There is often a need to change products or pallet patterns.
Flexibility is needed for the production process.
Work must be done in the same production area.
Space is limited for building up robotic cells.
The manufacturer wants a flexible approach to palletizing robots.
The robot type, gripper, and safety configuration will always depend on the actual application.

In each case, the correct selection of robot, gripper, and safety setup will depend on the application at hand.

High Throughput Industrial Palletizing Robots

In situations where throughput, weight handling, and non-stop operating ability are the most important criteria, an industrial palletizing robot may do the job.

Industrial robots are often used in high-throughput palletizing operations for product or case positioning.

Designed For Harsh Production Needs

The palletizing robots used in industry are well suited for production lines in which there is a need for large amounts of products to be handled or if heavy loads are being handled.

In some cases, they may provide sufficient speed, precision, and range to make them useful in large-scale end-of-line automation.

This is especially helpful in sectors like food and beverages, domestic chemicals, construction materials, and logistics, where efficient palletizing may influence handling and transportation.

Integration With the Production Line

The industrial robot should not be viewed in isolation.

The effectiveness of its performance relies on how efficiently it interacts with upstream conveyors, product handling equipment, pallet supply, pallet discharge, and other parts of the production line.

This is the reason why packing automation needs more than just the selection of the right robot.

When Should an Industrial Palletizing Robot Be Considered?

Industrial palletizing robots could be considered when:

There is relatively high production output.
There is a need for higher payload capacity for products or cases.
Good palletizing accuracy is required.
A production line needs a dedicated robot cell.
There are future plans for more comprehensive automation on the line.

Five Points To Take Into Account Prior To Choosing A Packing Automation System

The choice between several robotic systems becomes much simpler when one begins from the production line and not the robot.

1. Product Type

Which kind of product will be handled by the system?

There can be various differences between products such as size, shape, weight, packaging material, and stability. All these features determine which gripper and robotic configuration will be necessary.

For instance, bottles, sacks, cartons, and construction material will be processed in different ways.

2. Format of packaging

The packaging procedure must also be clearly defined.

Does the robot place individual products in a box, does it take care of ready-made boxes, or does it load products on pallets?

There can be a significant difference in choosing an application in case of case packing and palletizing processes, despite the fact that the processes are performed on the same production line.

3. Throughput of the production

The throughput of the production is one of the most critical parameters in the automation process.

A manufacturer should not only consider existing production demands but also the forecasted ones.

It is important that the solution that performs effectively in the current production situation will also perform effectively in any new production situations in the future.

4. Changeover between products and flexibility

How often is there a need to change products or packaging on the production line?

If the line produces a standardized product, speed and repeatability will probably be more important than the others.

If there is manufacturing of several products, it will be better to pay attention to flexibility and changeover efficiency.

5. Factory Layout and Integration

Space available, conveyor placement, pallet placement, and connection with other equipment will all influence the ultimate design of the system.

With existing facilities, the automated system must integrate itself into the existing process flow.

Here, system integration becomes particularly critical. A good system will need to consider the entire flow of materials instead of considering the robot to be an isolated unit.

Packaging Automation: What System Is Right for You?

Below is a comparison to give you a rough idea of the three robotic systems mentioned.

Criteria	Twin-axis Case Packing	Collaborative Palletizing	Industrial Palletizing
Main application	Case packing and loading	Flexible palletizing	High-volume palletizing
Movement approach	Linear movement	Collaborative articulated movement	Industrial robotic movement
Key advantage	Efficient and repeatable case packing	Flexibility	Speed, reach, and load-handling capability
Production flexibility	Moderate	High	High, depending on system configuration
Space consideration	Overhead configuration can save floor space.	Compact layouts may be possible.	Requires a dedicated robotic working area
Best suited for	Predictable case-packing tasks	Flexible production requirements	Demanding, high-volume applications

The table serves as a general guideline. However, the proper choice of solution would depend on the product being handled, packaging process, throughput, payload, factory layout, and other specific factors.

Think About the Complete End-of-Line System

One of the key factors in packaging automation is the understanding that the robot is just one element of the total manufacturing system.

In order for a casepacking/palletizing robot to function properly, it should work together with conveyors, handling devices, packaging machinery, and other systems.

When developing a completely new automated line, it gives an opportunity to build the entire flow of materials from the very beginning.

If there is an existing plant, then the same approach is valid since the new automation system should fit into the existing production process, taking into account such factors as limited space, product flow, and others.

Techflowbot specializes in integrating robotic systems for case packing, palletizing, and depalletizing processes so the entire automation project can be designed based on the actual requirements of the production line.

Robotic case packing and palletizing system for end-of-line automation

A Practical Solution for Selecting Packaging Robots

There is no robot that is universally applicable to all production settings.

A two-axis robotic case packing machine can be suitable for structured and repeatable case packing. Collaborative palletizing systems may offer more adaptability in variable production settings. Industrial palletizers can be preferable in difficult applications where speed and load handling are essential considerations.

The best way is to start from the requirements of production:

What items should be handled?
What type of packaging is necessary?
What level of speed is needed?
What is the frequency of changes of products or requirements?
What payload and reach are needed?
How much space is available?
How should the robot fit into the production line?

Having answered all these questions, the right robotic architecture will become much clearer.

While assessing the possibility of applying automation to packaging, it should be noted that the purpose is not to automate only a particular process. The purpose is to develop a robust, flexible, and integrated end-of-line system that helps to support the manufacturing process now and can meet further demands.

The right set of robotic equipment, proper product handling, and integration will allow manufacturers to enhance production efficiency through better consistency and optimization of material flows.