The Challenge
Automating Heavy Pallet Builds with Mixed Case Formats
The customer required a scalable solution that could safely stack heavy pallets while managing varied box sizes and limited space. Their requirements included:
- Handling pallets with loads up to 1,500 lbs
- Accommodating multiple case sizes and stacking patterns
- Maintaining automation within a compact footprint
- Facilitating fast pallet builds without forklift rehandling
MWES was selected to design a compact robotic cell using mobile floortrack robotics to safely and efficiently build high-volume pallets.
The Solution
Floortrack-Mounted Robot Cell with Dynamic Pallet Control & Layer Logic
MWES provided a turnkey palletizing solution featuring:
- A Fanuc M-410iB robot on a flexible floortrack base to reach multiple stacking zones
- Integrated boxing conveyors and pallet dispensers with slip-sheet insertion
- Recipe-based HMI for pattern-driven layer formation with mixed case sizes
- Autonomous pallet wrapping and sequenced transfer to shipping
- Safety-rated guard interlocks, e-stops, and monitoring systems
MWES delivered a compact, high-mix palletizing system that automates loading, stacking, wrapping, and staging of heavy pallets with minimal operator interaction.
The Results
High-Throughput Palletizing with Reduced Labor and Flexible Capacity
The cell delivered significant operational efficiencies:
- Pallet build rates in excess of four layers per minute, depending on load mix
- Automated handling of mixed case trays without reconfiguration
- Eliminated arduous manual lift operations and forklift staging
- Provided scalable throughput while minimizing footprint and staffing needs
This upgrade enabled the customer to automate complex palletization patterns quickly and safely—boosting productivity and operational resilience with flexible payload handling.
