Custom Palletizing Solution

A large consumer goods packaging manufacturer faced a convergence of operational challenges that threatened production continuity. With roughly 100 different packaging formats requiring palletization, no off-the-shelf equipment existed that could handle the required variability — multiple OEMs were approached and none could meet the specification. Compounding this, chronic labor shortages meant shifts were frequently cancelled when workers failed to show up, forcing production shutdowns. The facility also piped in live steam to run presses and other equipment, creating genuine workplace hazards for manual palletizing operators. Together, these issues created persistent downtime, constrained throughput, and an unsafe working environment.

Concept Systems, a Rockwell Automation Gold PartnerNetwork member, designed a custom palletizing cell built around a fully integrated Rockwell Automation control architecture. The system combined automated case erecting, robotic palletizing using FANUC robots and cobots, and integrated conveyance — none of which was available as a standard off-the-shelf solution. The control layer uses ControlLogix programmable controllers paired with Compact GuardLogix with CIP Safety for deeply integrated machine safety, while PanelView graphic terminals provide facility-wide HMI access from any point on the floor. PowerFlex variable frequency drives and I/O modules complete the hardware stack. The solution was engineered specifically around the brownfield facility's spatial constraints and existing equipment, rather than a generic deployment.

The new palletizing system enabled the packaging manufacturer to run seven production lines simultaneously — up from three — without increasing headcount. Previously, labor shortages forced shift cancellations and facility shutdowns; the automated system eliminated that dependency and allowed the facility to run longer at higher efficiency. Key outcomes include:

• Production lines expanded: 3 → 7 using the same personnel
• Facility uptime: Eliminated shift cancellations caused by labor no-shows
• Employee safety: Operators relocated away from steam equipment and hazardous processes through scanner integration, safety-rated robotics, and collaborative robot deployment
• Throughput: Additional capacity delivered beyond initial project expectations

• When no standard equipment meets your variability requirements, a custom-engineered solution from a systems integrator may be the only viable path — brief multiple OEMs before concluding the market can't support your needs.
• Labor shortage risk is a legitimate design input: automation that removes shift-dependency from production continuity delivers ROI even before efficiency gains are counted.
• Integrated safety architecture (CIP Safety, collaborative robotics, area scanners) is more sustainable than physical barriers alone — it allows operators to work near automation without being excluded from the cell.
• Brownfield constraints should be scoped early; facility geometry and existing equipment directly shape what automation configurations are feasible.