What are the different palletizing robot types and how do they work?

Today's palletizing systems come in many forms, each suited to different production environments, payloads, and budgets. While designs vary, they all share the same goal: transferring packaged goods from a conveyor or workstation onto pallets quickly and accurately.

Six-axis palletizing robots

The six-axis palletizing robot is by far the most common and versatile option. A single articulated arm can reach multiple pallets, handle a range of product sizes, and stack in complex patterns. Because of their flexibility and reach, six-axis robots dominate large-volume operations where layouts may change or packaging sizes vary.

They are proven, adaptable, and compatible with many types of grippers, but they do require more space than linear systems and can be slightly more complex to program when floor space is tight. Six-axis palletizers are ideal for medium- to high-volume lines where reliability and versatility are both essential.

Collaborative palletizers (cobots)

Collaborative palletizers – often called cobots – offer a smaller and more accessible alternative. Designed to work safely near people, often without full safety fencing, they have become popular among small and mid-sized manufacturers that need to automate without redesigning their entire workspace.

Their main advantages are simplicity and flexibility: cobots are quick to install, easy to move, and straightforward to reconfigure for new products. However, they have lower payload capacities and slower cycle times than industrial robots, which limits them to lighter goods or slower production rates. They work best in low- or moderate-throughput environments and plants that handle frequent product changeovers.

Gantry or cartesian palletizers

Gantry or cartesian palletizers move along fixed linear axes instead of rotating joints. They are the workhorses of stable, high-volume production, known for excellent precision, repeatability, and reliability. Their simple mechanical design makes them durable and capable of handling very heavy payloads for years with minimal maintenance.

The trade-off is flexibility. Because their structure is fixed, changing the layout or adapting to a new product can be expensive and time-consuming. These systems are best suited for standardized, long-running operations where consistency and payload capacity outweigh flexibility.

Mobile and AMR-based palletizers

A newer but increasingly common option is the mobile or AMR-based palletizer, where a compact robot or cobot is mounted on an autonomous mobile base. This allows one unit to move between multiple lines or workstations as needed, balancing workloads and optimizing floor space.

Mobile palletizers provide unmatched flexibility and can be scaled up easily as demand grows. Their limitations are mainly speed and payload – they handle lighter, slower operations—and their technology is still evolving toward the robustness of fixed systems. They are proving effective in facilities with several small lines or seasonal product changes.

The importance of end-of-arm tooling (EOAT)

Beyond the robot itself, the end-of-arm tooling – or gripper – often determines how well the system performs. Vacuum grippers with suction cups excel at lifting cartons and bags, while mechanical clamps or magnetic grippers handle heavier or irregular shapes. The gripper’s design affects speed, reliability, and even product care.

“The gripper is what connects the robot to the product, and that’s where many palletizing systems succeed or fail,” says Mikkel Viager, Principal Advisor at HowToRobot. “The good news is you don’t have to know the technical details yourself – you just need a supplier who has experience with your type of products and knows which gripper technologies will handle them best.”

For buyers, that means focusing less on the robot brand and more on finding an integrator or supplier who understands the products being handled. A good supplier will know which gripper technology is proven for your application and can either design the cell around that choice or provide a standard palletizing solution that already fits your needs.

Pre-engineered and vision-guided palletizing cells

Modern palletizing cells have also become faster and easier to deploy thanks to pre-engineered, plug-and-play systems that combine standard hardware with configurable software. These modular cells can often be installed in days rather than weeks or months, enabling companies with limited engineering resources to start small and expand later.

Many current systems incorporate vision-guided stacking, allowing robots to detect box orientation or adjust automatically for variation – a capability that until recently required custom integration. These advances have made palletizing a more standardized, repeatable, and affordable automation task for companies of all sizes.

Let the integrator propose the right solution type

While it’s useful to understand the different robot types and their characteristics, deciding which one to use is rarely the buyer’s responsibility. In most cases, the optimal choice depends on a mix of product weight, throughput, floor space, and handling requirements.

The most effective approach is to describe your process and goals clearly, then let qualified system integrators propose the robot type and setup they believe best fit your needs. Different suppliers often reach the same performance target in different ways – and comparing those proposals is one of the most revealing steps in finding the right solution.

What to plan and look out for when automating palletizing?

Even proven technology can underperform if a project isn’t scoped correctly.

Before launching a palletizing project, manufacturers should take time to align expectations, layout, and integration needs.

1. Clarify your objectives.

Is the main driver labor reduction, ergonomics, or throughput stability? Each goal affects the solution design, ROI expectations, and equipment choice.

2. Evaluate your space.

End-of-line areas are often tight. Consider conveyor positions, pallet drop-off points, ceiling height, and room for forklifts or AMRs. Proper planning avoids last-minute compromises that limit performance.

3. Understand your product mix.

Different box sizes, weights, and packaging materials can affect grip reliability. Frequent product changes may require quick-change tooling or flexible programming.

4. Integrate safety early.

Safety scanners, light curtains, or physical barriers are standard. Plan for them from the start to ensure compliance and protect operators.

5. Think system-wide.

Palletizing rarely stands alone. It often connects to wrapping, labeling, or warehouse transport. Early integration planning prevents bottlenecks later.

Common pitfalls include over-specifying features that add cost without benefit, neglecting space constraints, and failing to compare supplier proposals on equal terms.

“We often see manufacturers skip the comparison step – and end up paying more for a less optimal outcome,” says Viager. “A better approach is to define your needs clearly and see how multiple suppliers would tackle them.”

Who are the palletizing suppliers?

The global palletizing automation market is large and diverse.

Supplier data compiled by HowToRobot shows that more than 1,000 companies worldwide specialize in packing and palletizing automation – about 9.7 percent of all automation suppliers. These include turnkey system integrators, robot and component manufacturers, distributors, and advisors.

The abundance of suppliers means there is almost always a fitting solution available – but identifying it can be time-consuming. Each supplier may interpret a project differently, and comparing proposals can be difficult without a structured process.

“The challenge isn’t availability – it’s transparency,” says Peters. “Manufacturers often don’t know which suppliers are relevant or what’s realistic for their budget. That’s where our data and network can make a big difference.”

Manufacturers today have more options than ever. The key is knowing how to navigate them efficiently – using the market to reveal what’s feasible, rather than guessing internally.

How to find the right palletizer – and the supplier to provide it?

The best palletizing system isn’t necessarily the most advanced – it’s the one that best fits your process, space, and budget.

Finding that fit means engaging with the supplier market early and letting multiple experts propose solutions based on your specific needs.

Instead of designing the entire concept at first, describe your current process – product types, packaging rates, space, and desired outcomes – and see how suppliers would solve it. Comparing several solution concepts side by side gives you a realistic picture of cost, lead time, and performance before you commit.

Manufacturers can now do this directly through HowToRobot’s platform, which streamlines the automation sourcing process. Instead of researching and contacting suppliers one by one, companies describe the process they want to automate in a few steps. The platform turns that description into a brief that is automatically shared with relevant suppliers, who respond with solution concepts and indicative price ranges. It gives buyers a clear and quick overview of what’s possible – and from whom – before any detailed engineering or sales discussions begin.