CASE STUDY | Bundle palletizer with multi-functional end-of-arm tooling
By: Alyssa Bardol
Automating palletizing for a new U.S. production line
A building products manufacturer was launching a new U.S. facility to support rising demand for its finishing compound product. At the start of the quoting process, the product was still being shipped from overseas but market demand had justified a full domestic line. They needed a robotic palletizing system that could support startup production while remaining flexible enough to scale with any future growth for their new facility.
The challenge: Palletize bundles from a multi-OEM line
The line included equipment from multiple OEMs: a filler and bundler upstream and a stretch hooder downstream. They needed to palletize the bundles being generated upstream. To do that, they needed to place a pallet, place a slip sheet and start stacking loads on those pallets.
The standard approach would be three separate pieces of equipment to handle each function: a pallet dispenser, a slip sheet dispenser and a robotic palletizing cell. That increases footprint, cost and maintenance overhead.
We took a different path:what if the robot could do all three?
The PASCO approach: Design around the robot
What made this different wasn’t just the tooling alone, it was how we approached the problem.
We look at the rate, the space and what the robot can realistically handle. Then we ask what’s actually necessary. In this case, once we assessed the rates they needed to meet and the capability of the robot itself, we realized the robot had the bandwidth to do more than just palletize. So we designed the tooling to let it handle multiple functions.
We build systems this way on purpose. Not over-complicated. Not overbuilt. Clean, efficient, and designed to scale with the customer, not fight them later.
The end-of-arm tool was designed in-house to handle all three functions. That decision removed two major subsystems entirely, which made the cell smaller in size, easier to maintain and more cost effective for the customer. The robot stayed active throughout each cycle, doing more with every move.
By consolidating those functions into a single tool, the robot became the core material handler of the system, reducing the overall component count. That translates directly to lower capital cost, fewer failure points and shorter install time.
Why slower rates were a design advantage
The customer’s initial required production rate was relatively modest, which made this multifunctional tooling strategy a perfect fit. Because the robot wasn’t under time pressure, it could perform all three tasks without compromising cycle time. This gave us the freedom to design for function, not just speed.
And like every system we build, it wasn’t just designed for startup. The robot, EOAT and cell were all sized to support higher speeds and future throughput with no redesign needed.
Seamless integration across OEM boundaries
The bundle palletizer was designed to install between upstream and downstream equipment from different providers. Thanks to a clean plant layout provided early in the project, we were able to dimension the system precisely and align every handoff point — pallet entry, bundle pickup, final stack discharge — with surrounding systems.
Even when working with multiple OEMs, the integration held up because everything on our side was engineered for clarity and fit.
Built for practical efficiency
We focused on where automation would create the most value, not the most complexity. The result is a robotic palletizing system that:
Handles three functions with one robot
Has fewer moving parts and simpler maintenance
Fits tight footprints in new facilities
Integrates cleanly with third-party equipment
Leaves headroom to scale with production growth
Results at a glance
Multifunctional EOAT: One tool handles pallets, slip sheets, and product
Lower total cost of ownership: Fewer devices, fewer maintenance points
Robot-driven efficiency: Smarter tooling with fewer wasted movements
Tight integration: Aligned precisely with upstream and downstream systems
Scalable design: Ready to support future throughput increases
Ready to optimize your palletizing process?
Looking for a robotic palletizer that works harder without costing more? Let’s talk about how smart tooling and efficient design can deliver more from day one and keep delivering as your line evolves.
What are the common applications of industrial automation?
The common applications of industrial automation include packaging, palletizing, material handling, quality control, and customizable robotic systems, which help manufacturers enhance efficiency, precision, and reliability in their production processes.
What are the benefits of automated palletizing systems?
Automated palletizing systems offer increased efficiency, consistency, and worker safety by automating the repetitive task of stacking products onto pallets. This helps improve productivity, reduce labor costs, and minimize the risk of injuries.
How does automated equipment enhance product quality?
Automated equipment enhances product quality by ensuring consistent and precise manufacturing processes, reducing human error, and maintaining high standards of production efficiency and reliability in industrial environments.
What is the initial investment for automated equipment?
The initial investment for automated equipment can vary depending on the complexity and scale of the system, but it typically requires a significant upfront capital expenditure to purchase and install the necessary hardware and software.
How does industrial automation improve worker safety?
Industrial automation can enhance worker safety by reducing manual handling, minimizing exposure to hazardous environments, and automating repetitive tasks, thereby mitigating the risk of workplace injuries.
What types of industries use automated equipment most?
Industries that rely heavily on automated equipment are typically those with high-volume, repetitive manufacturing processes, such as automotive, food and beverage, consumer goods, building products, landscape products and more These industries leverage automation to improve efficiency, consistency, and safety in their operations.
What is the primary goal of industrial automation in manufacturing?
The primary goal of industrial automation in manufacturing is to improve efficiency, productivity, and reliability by leveraging technologies such as robotics, control systems, and data analytics to streamline production processes.
What are the benefits of using automated equipment in manufacturing?
Using automated equipment in manufacturing can provide increased efficiency, precision, and consistency in production processes, leading to improved product quality, reduced labor costs, and increased productivity.
Can automated equipment be integrated with existing systems?
Automated equipment can be seamlessly integrated with existing systems, allowing for a smooth transition and optimized performance across manufacturing processes.
What is the role of robotics in industrial automation?
Robotics play a crucial role in industrial automation, enabling manufacturers to automate repetitive tasks, improve efficiency, and enhance productivity in various industrial processes, particularly in packaging and palletizing operations.
What types of products are commonly palletized?
A wide variety of products are commonly palletized, including boxes, crates, bags, and other packaged goods, as palletization helps streamline transportation and storage of these diverse industrial and consumer items.
How does industrial automation reduce production costs?
Industrial automation can reduce production costs by increasing efficiency, minimizing labor, and improving process consistency, leading to higher output and decreased operational expenses.
Can industrial automation replace human workers completely?
While industrial automation can significantly streamline and enhance production processes, it is unlikely to completely replace human workers entirely. Automation complements human skills, but certain tasks still require unique human capabilities.
