Start from the case flow, not the robot

A palletizing quote is only as good as the data behind it. Before talking to integrators, collect:

• Line rate per SKU, including the peak rate, not only the average.

• Case dimensions and weights, including the heaviest and least stable product.

• Pallet patterns — cases per layer, layers per pallet, slip sheets.

• Shift pattern and planned stops.

Layer cycle is the number that matters

A robot's datasheet speed is not your capacity. What counts is the layer cycle: the time to place one full layer, including gripper moves and slip sheets. Capacity per cell = cases per layer × 3,600 ÷ layer cycle in seconds.

Example: 10 cases per layer at a 31 s layer cycle gives about 1,160 cases/h per cell.

Leave margin for pallet changes

Every full pallet must leave and an empty one must arrive. If the cell stops during the exchange, accumulation upstream has to absorb it. Size accumulation for the exchange time plus the longest short stop you expect.

One cell or two?

Two cells cost more but give redundancy: during maintenance one cell can run the line at reduced rate. For lines where a stop is expensive, this is often the deciding factor.

Questions to ask at quotation

1. What layer cycle is guaranteed for my heaviest pattern?

2. How are new patterns created, and by whom?

3. How is the pallet exit guarded, and how is it tested?

4. What is the changeover time between patterns, and what does it include?