Project
PRJ-0312
Industry
Food & Beverage
Application
End-of-line palletizing
Commissioned
Nov 14, 2025
Status
Commissioned
Line output raised from 900 to 1,200 cases/h by removing manual palletizing as the constraint.
Project
PRJ-0312
Industry
Food & Beverage
Application
End-of-line palletizing
Commissioned
Nov 14, 2025
Status
Commissioned
Line output raised from 900 to 1,200 cases/h by removing manual palletizing as the constraint.
FIG. 1
End-of-line palletizing
PRJ-0312
01
Commissioning results
Measured outcome
01
Commissioning results
Measured outcome
Line output
900
→
1,200
cases/h
12-week average after SAT · 2 shifts · same SKU mix
Line output
900
→
1,200
cases/h
12-week average after SAT · 2 shifts · same SKU mix
Manual palletizing positions
2
→
0
per shift
4 operators/day redeployed to line roles; no redundancies
Manual palletizing positions
2
→
0
per shift
4 operators/day redeployed to line roles; no redundancies
Cell availability
98.6
%
Rolling 90 days · palletizing cells only, upstream stops excluded
Cell availability
98.6
%
Rolling 90 days · palletizing cells only, upstream stops excluded
Simple payback
19
months
€410,000 installed ÷ €260,000 estimated annual benefit (client cost data)
Simple payback
19
months
€410,000 installed ÷ €260,000 estimated annual benefit (client cost data)
02
Engineering record
Challenge, approach and architecture
02
Engineering record
Challenge, approach and architecture
Challenge
Context. A bottling line producing 24 SKUs in 6- and 12-packs. Filling and case packing had been upgraded to 1,500 cases/h, but cases were still stacked by hand on two pallet positions.
Existing process. Two operators per shift stacked 10 cases per layer, 6 layers per pallet, at up to 900 cases/h. Output dropped late in each shift and on hot days, and lifting risk was the plant's top ergonomic finding.
Constraints.
No extension of the building; the cells had to fit the existing 14 × 9 m end-of-line area.
Installation within a 10-day summer shutdown.
Pattern changes by line operators, without robot programming.
Challenge
Context. A bottling line producing 24 SKUs in 6- and 12-packs. Filling and case packing had been upgraded to 1,500 cases/h, but cases were still stacked by hand on two pallet positions.
Existing process. Two operators per shift stacked 10 cases per layer, 6 layers per pallet, at up to 900 cases/h. Output dropped late in each shift and on hot days, and lifting risk was the plant's top ergonomic finding.
Constraints.
No extension of the building; the cells had to fit the existing 14 × 9 m end-of-line area.
Installation within a 10-day summer shutdown.
Pattern changes by line operators, without robot programming.
Engineering approach
We modelled case flow for the full SKU mix and found that one cell could not cover peaks with enough margin for pallet changes. The design uses two identical cells fed by a diverter, so either cell can run the whole line at reduced rate during maintenance.
Scope. Throughput model, layout and safety concept; two ABB palletizing robots with vacuum/clamp grippers; infeed conveyors, diverter and accumulation; pallet dispensers; line PLC on Siemens S7-1500; pattern editor on the HMI.
Patterns were built and tested on a full-scale mock-up in our integration hall before FAT.
Engineering approach
We modelled case flow for the full SKU mix and found that one cell could not cover peaks with enough margin for pallet changes. The design uses two identical cells fed by a diverter, so either cell can run the whole line at reduced rate during maintenance.
Scope. Throughput model, layout and safety concept; two ABB palletizing robots with vacuum/clamp grippers; infeed conveyors, diverter and accumulation; pallet dispensers; line PLC on Siemens S7-1500; pattern editor on the HMI.
Patterns were built and tested on a full-scale mock-up in our integration hall before FAT.
System architecture
Line control: one S7-1500 safety PLC for both cells, conveyors and pallet handling, PROFINET to robots and drives.
Robots: two 4-axis palletizing robots, 180 kg payload, each with a dedicated pallet exit.
Safety: fenced cells, muted light curtains on pallet exits, safety laser scanner at the operator pallet station.
Data: cell state, cycle and fault data to the plant historian via OPC UA.
System architecture
Line control: one S7-1500 safety PLC for both cells, conveyors and pallet handling, PROFINET to robots and drives.
Robots: two 4-axis palletizing robots, 180 kg payload, each with a dedicated pallet exit.
Safety: fenced cells, muted light curtains on pallet exits, safety laser scanner at the operator pallet station.
Data: cell state, cycle and fault data to the plant historian via OPC UA.
Deployment & commissioning
FAT ran over three days with the client's operators, using production cases. Installation and commissioning took 9 of the 10 shutdown days; ramp-up to full rate took two weeks.
One item remained open at SAT: pattern changeover averaged 12 minutes against a 10-minute specification. The cause is the manual slip-sheet magazine change; a second magazine is scheduled.
Deployment & commissioning
FAT ran over three days with the client's operators, using production cases. Installation and commissioning took 9 of the 10 shutdown days; ramp-up to full rate took two weeks.
One item remained open at SAT: pattern changeover averaged 12 minutes against a 10-minute specification. The cause is the manual slip-sheet magazine change; a second magazine is scheduled.
- INInfeedCases from case packer
- DIVDiverterSplit to cell A / B
- ROBPalletize10 cases per layer
- EXITPallet exitMuted light curtain
- WRAPStretch-wrapLabel and dispatch
03
Specification & results
Specification, acceptance and results
03
Specification & results
Specification, acceptance and results
Cells
Identical, either cell can run the line
2
Cells
Identical, either cell can run the line
2
Robot payload
4-axis palletizing robot
180 kg
Robot payload
4-axis palletizing robot
180 kg
Pattern
60 cases per pallet
10 cases/layer · 6 layers
Pattern
60 cases per pallet
10 cases/layer · 6 layers
Footprint
Within existing end-of-line area
14 × 9 m
Footprint
Within existing end-of-line area
14 × 9 m
Controller
PROFINET / PROFIsafe
Siemens S7-1500F
Controller
PROFINET / PROFIsafe
Siemens S7-1500F
Parameter
Specified
Measured
Result
Layer cycle time
≤ 34 s
31 s
Pass
Layer cycle time
Specified
≤ 34 s
Measured
31 s
Result
Pass
Two-cell capacity
≥ 1,500 cases/h
2,322 cases/h
Pass
Two-cell capacity
Specified
≥ 1,500 cases/h
Measured
2,322 cases/h
Result
Pass
Pattern recognition
≥ 99.5 %
99.8 %
Pass
Pattern recognition
Specified
≥ 99.5 %
Measured
99.8 %
Result
Pass
Pattern changeover
≤ 10 min
12 min
Open item
Pattern changeover
Specified
≤ 10 min
Measured
12 min
Result
Open item
Results
Measure | Before | After |
|---|---|---|
Line output | 900 cases/h | 1,200 cases/h |
Constraint | Manual palletizing | Filler |
Palletizing operators | 2 per shift | None (redeployed) |
Pattern change | Paper instruction | HMI recipe |
Each cell is capable of about 1,160 cases/h (10 cases per 31 s layer), so two cells provide 2,322 cases/h against a 1,500 cases/h specification. The line is now limited by the filler, not by palletizing.
Estimated annual benefit of €260,000 = 2 operators × €34/h × 8 h × 2 shifts × 250 days (€272,000), less €12,000 annual maintenance.
Results
Measure | Before | After |
|---|---|---|
Line output | 900 cases/h | 1,200 cases/h |
Constraint | Manual palletizing | Filler |
Palletizing operators | 2 per shift | None (redeployed) |
Pattern change | Paper instruction | HMI recipe |
Each cell is capable of about 1,160 cases/h (10 cases per 31 s layer), so two cells provide 2,322 cases/h against a 1,500 cases/h specification. The line is now limited by the filler, not by palletizing.
Estimated annual benefit of €260,000 = 2 operators × €34/h × 8 h × 2 shifts × 250 days (€272,000), less €12,000 annual maintenance.
04
Drawings
Layout and detail drawings
Original technical drawings prepared for this record. Illustrative, not to scale.
04
Drawings
Layout and detail drawings
Original technical drawings prepared for this record. Illustrative, not to scale.
FIG. 1 · Two-cell palletizing, plan view
FIG. 2 · Layer patterns, 10 cases per layer, 6 layers
The palletizer stopped being the conversation in the morning meeting. Now we talk about the filler.
Operations Manager
Client · beverage producer (anonymized)
PRJ-0312
05
Related
Solutions, platforms and resources
05
Related
Solutions, platforms and resources
A
Related solutions
B
Technology stack
C
Related resource
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