In the dynamic world of logistics and manufacturing, processes are becoming increasingly complex. One of the challenges many companies face is efficiently stacking mixed products onto a single pallet – also known as mixed palletising. Thanks to the use of collaborative robots (cobots), this challenge is becoming more manageable. In this blog, we’ll explain what mixed palletising is, what advantages it offers, and why cobots are the ideal solution.
What is mixed palletising?
Mixed palletising is the process of stacking different products – varying in size, weight, or packaging – onto one pallet. This often occurs in order picking for customers who require a combination of items in a single shipment. Think of distribution centers, e-commerce companies, or manufacturers with diverse product lines.
The challenges of mixed palletising
Traditional (automated) palletising typically involves one product type at a time. Mixed palletising, however, introduces a variety of complexities:
Different shapes and sizes
Load stability
Optimal use of pallet space and height
Complex stacking sequences
High flexibility requirements
As a result, manual mixed palletising is labor-intensive, error-prone, and difficult to scale.
Cobots as smart palletising partners
Cobots are particularly well-suited for mixed palletising. They combine strength and precision, are flexible in deployment, and can be quickly adapted to changing product flows. Unlike traditional industrial robots, cobots don’t require large safety cages and can work safely alongside humans.
Key Benefits of Mixed Palletising with Cobots:
Flexibility: easy to program for new products or stacking patterns.
Space-saving: compact work cells without the need for safety fencing.
Scalability: easily scalable to meet growing demand.
Consistent quality: precise and repeatable stacking every time.
Cost savings: reduced product damage and lower physical strain on workers.
Real-world example
At WiredWorkers, we’ve helped several clients automate their mixed palletising processes. With the help of smart vision technology, palletising software, and a custom-designed gripper, even the most varied products can be stacked efficiently.
Ready for the future
Mixed palletising is no longer a luxury – it's a necessity in a world where customization and speed are more important than ever. By implementing cobots, companies become more agile, more efficient, and more attractive to employees.
WiredWorkers is an expert in automation and has already helped several companies implement collaborative robots. Want to learn more about how to integrate cobots safely and efficiently? Contact us or schedule a free cobot consultation!
