How PASCO keeps end-of-line systems running: the engineering behind uptime
By: Alyssa Bardol
When manufacturing engineers evaluate robotic palletizers, case packers, and material handling systems, published speed is only half the equation. The metric that governs whether a line hits its numbers is availability: the percentage of scheduled production time a system actually runs without unplanned stops.
Availability depends on two things: how often a system stops (mean time between failures, or MTBF) and how quickly it gets running again (mean time to repair, or MTTR). PASCO®, a St. Louis OEM manufacturer of end-of-line automation since 1976, has installed 1,200+ systems across 900+ facilities. Its approach to availability starts with engineering choices at the structural, electrical, and support levels.
1. Mechanical architecture: built for real plants
Forklifts hit equipment. Dust and debris build up. Operators push systems to their limits every shift. Much unplanned downtime at the end of the line traces back to equipment that wasn’t built for those conditions.
Structural steel construction. PASCO systems are fabricated from structural steel channel at PASCO’s St. Louis facility, where cutting, welding, and machining are part of everyday production. Durability is the baseline, not an add-on. See why in-house manufacturing matters.
Roller conveyors that hold speed. PASCO belt-driven live roller (BDLR) conveyors use Poly-V belts instead of rubber bands, so grip stays consistent and belts don’t stretch. For pallet handling, PASCO chain-driven live roller (CDLR) conveyors use heavy-duty chains engineered to the load and to OSHA standards.
End-of-arm tooling built in-house. PASCO designs and manufactures its end-of-arm tooling for each product and environment. PASCO tooling routinely exceeds 5 million cycles before overhaul.
Engineered for harsh environments. PASCO builds for corrosive chemicals in paint and coatings and petrochemical plants, abrasive materials like cement and sand in building products, wet and freezing conditions in ice production, and Class I Division I and II hazardous locations.
Subsystem
Common failure point
PASCO approach
Effect on uptime
Roller conveyor drives
Rubber band drives that stretch and slip
Poly-V belt drives
Consistent roller speed without belt stretch
Pallet handling
Conveyors not sized for the load
Heavy-duty CDLR engineered to load requirements and OSHA standards
Routinely exceeds 5 million cycles before overhaul
Structure
Frames damaged by plant traffic and debris
Structural steel channel, fabricated in-house
Built to take daily plant abuse
2. Electrical and control integrity: visibility without lock-in
Unplanned stops get longer when maintenance teams can’t see what the system is doing, or can’t get replacement parts without going back to the original vendor.
Control panels built in-house. PASCO designs and builds every structure, control panel, and electrical enclosure at its St. Louis facility. For wet and corrosive environments, such as ice production and petrochemical plants, PASCO uses climate-controlled electrical panels.
I/O-Link diagnostics. PASCO systems include I/O-Link-enabled diagnostics that give operators and maintenance teams real-time performance data and historical trends for every shift.
No proprietary lock-in. PASCO provides original part numbers for every motor, sensor, and actuator, so plants can source replacement components locally instead of waiting on PASCO.
Rockwell Automation Gold OEM Partner. Pasco Systems Corp holds Gold OEM Partner status in the Rockwell Automation PartnerNetwork.
3. Rapid recovery and lifecycle support
Every system eventually needs wear parts and service. What matters is how fast the line gets running again. PASCO supports every system with the same in-house team that engineered and built it. See how PASCO parts and service works.
Three-ring phone answer. When a PASCO customer calls, a real person answers within three rings. There are no phone trees, and the person who picks up knows the system because PASCO built it.
Immediate remote diagnostics, 24-hour on-site aim. When a line goes down, PASCO starts remote diagnostics immediately and aims to be on-site within 24 hours, with PASCO technicians rather than subcontractors.
1,200+ parts stocked. PASCO stocks 1,200+ parts at its St. Louis headquarters, and most ship same-day. Non-stocked parts are quoted in under an hour.
FANUC Certified Service Provider. Fewer than 5% of FANUC integrators hold Certified Service Provider status. It authorizes PASCO technicians to perform robot warranty repairs at the same level as FANUC factory engineers, so one call covers the full system.
Tested before it ships. PASCO validates and tests complete systems at its own facility before installation, so issues are caught before the equipment reaches the plant floor. See PASCO’s integration process.
Throughput buyback guarantee. Every PASCO system is engineered to a documented throughput target. If a system doesn’t hit its quoted throughput, PASCO buys it back.
Support for the life of the system. PASCO keeps engineering records on every build and repairs, retrofits, or replaces components on systems installed decades ago. Every system includes a one-year zero-cost warranty covering the full system, including robots.
Technical summary for plant engineers
Line availability = MTBF ÷ (MTBF + MTTR)
MTBF (mean time between failures): extended through structural steel fabrication, Poly-V conveyor drives, in-house end-of-arm tooling that routinely exceeds 5 million cycles, and equipment engineered for harsh environments
MTTR (mean time to repair): reduced through I/O-Link diagnostics, original part numbers with no proprietary lock-in, three-ring phone support, immediate remote diagnostics, 1,200+ same-day parts, and FANUC CSP robot service
Accountability: a documented throughput target on every system, backed by PASCO’s buyback guarantee, from a family-owned company that earns 70% of its business each year from returning customers
What are the common applications of industrial automation?
Common applications of industrial automation include packaging, palletizing, material handling, quality control, and assembly processes, helping manufacturers improve efficiency, consistency, and safety in their production workflows.
What are the benefits of automated palletizing systems?
Automated palletizing systems offer increased efficiency, accuracy, and consistency in packaging processes, enabling businesses to streamline operations, reduce labor costs, and enhance product quality.
How does automated equipment enhance product quality?
Automated equipment enhances product quality by ensuring consistent manufacturing processes, reducing human error, and enabling real-time quality control monitoring to identify and rectify issues promptly.
How does palletizing increase warehouse storage capacity?
Palletizing goods increases warehouse storage capacity by enabling the stacking and efficient organization of products, maximizing the use of vertical space and optimizing the overall storage area.
What is the initial investment for automated equipment?
The initial investment for automated equipment can vary depending on the complexity of the system, the features required, and the scale of the operation. Automated equipment can require significant upfront costs, but the long-term benefits of increased efficiency and reduced labor costs can often justify the investment.
Are there any safety concerns with automated equipment?
Safety is a key consideration with automated equipment. Proper safety protocols, training, and guarding measures are essential to mitigate risks and ensure safe operation in industrial settings.
How does industrial automation improve worker safety?
Industrial automation reduces worker exposure to hazardous tasks, minimizing safety risks and improving overall workplace safety by automating dangerous processes and reducing the need for human intervention.
How does palletizing improve supply chain efficiency?
Palletizing improves supply chain efficiency by enabling faster loading and unloading, reducing damage, and optimizing transportation and storage space, leading to streamlined logistics and cost savings throughout the supply chain.
How does industrial automation enhance product quality?
Industrial automation enhances product quality by ensuring consistent processes, reducing human error, and enabling real-time quality monitoring and control. This leads to improved accuracy, consistency, and reliability in product manufacturing.
What types of industries use automated equipment most?
Industries that rely heavily on automated equipment include manufacturing, packaging, warehousing, and logistics, where automated systems improve efficiency, productivity, and consistency in repetitive tasks.
What is the primary goal of industrial automation in manufacturing?
The primary goal of industrial automation in manufacturing is to improve efficiency, productivity, and consistency in the production process.
What safety concerns exist in palletizing operations?
Safety concerns in palletizing operations include potential hazards from heavy machinery, load instability, and product damage. Proper safety protocols, worker training, and equipment maintenance are crucial to mitigate these risks.
What are the benefits of using automated equipment in manufacturing?
The benefits of using automated equipment in manufacturing include increased efficiency, improved product quality, reduced labor costs, and enhanced safety in harsh industrial environments.
Can automated equipment be integrated with existing systems?
Yes, automated equipment can typically be integrated with existing systems. PASCO's automation solutions are designed for seamless integration, allowing clients to enhance their existing operations with advanced packaging and processing capabilities.
How does industrial automation improve production efficiency?
Industrial automation improves production efficiency by increasing speed, accuracy, and consistency of manufacturing processes, reducing human error and downtime, and enabling scalable, high-volume production.
How does automated equipment improve production efficiency?
Automated equipment improves production efficiency by enhancing speed, consistency, and reliability, enabling manufacturers to optimize workflows, reduce labor costs, and increase overall output.
What is the purpose of palletizing in a warehouse setting?
The purpose of palletizing in a warehouse setting is to efficiently stack and consolidate products onto a pallet, enabling secure and organized storage and transportation of goods.
How does automated equipment minimize production errors?
Automated equipment minimizes production errors by providing precise, consistent, and repeatable processes, reducing the likelihood of human errors and ensuring high-quality output in manufacturing operations.
What are the key features of automated equipment?
The key features of automated equipment include increased efficiency, improved consistency, reduced labor requirements, and enhanced safety in industrial processes such as packaging and manufacturing.
What are the main components of an industrial automation system?
The main components of an industrial automation system typically include sensors, programmable logic controllers (PLCs), motion control devices, human-machine interfaces (HMIs), and industrial communication networks.
Can automated equipment reduce labor costs?
Automated equipment can reduce labor costs by increasing efficiency, productivity, and throughput, while minimizing the need for manual labor in various manufacturing and packaging processes.
What is the role of robotics in industrial automation?
Robotics plays a crucial role in industrial automation by enhancing precision, speed, and efficiency in manufacturing processes, enabling businesses to optimize production, reduce errors, and increase overall productivity.
What types of products are commonly palletized?
Common products palletized are items such as packaged goods, boxes, crates, drums, and other bulk materials that can be stacked efficiently for storage and transportation.
What is the difference between industrial automation and Industry 4.0?
The difference between industrial automation and Industry 4.0 is that industrial automation refers to the use of control systems and technologies to automate industrial processes, while Industry 4.0 is a broader concept that encompasses the integration of advanced technologies, data, and connectivity to revolutionize manufacturing.
How does industrial automation reduce production costs?
Industrial automation reduces production costs by improving efficiency, reducing labor expenses, and increasing output consistency and quality, leading to lower overall operational costs.
Can industrial automation replace human workers completely?
Industrial automation can enhance productivity and efficiency, but completely replacing human workers may not be feasible or desirable in many industries due to the need for specialized skills, flexibility, and human judgment.
What industries use palletizing most frequently?
The industries that use palletizing most frequently are the manufacturing, food and beverage, and logistics sectors, where palletizing automates the stacking and loading of goods onto pallets for efficient storage and transportation.
Can palletizing be used for non-standard item sizes?
Yes, palletizing can be used for non-standard item sizes. PASCO's automated palletizing solutions are designed to handle a wide range of product dimensions and weights, ensuring efficient handling of diverse packaging requirements.
What is the cost of implementing a palletizing system?
The cost of implementing a palletizing system can vary depending on factors such as the complexity of the system, the specific equipment required, and the level of customization needed to meet the client's requirements.
What advancements are shaping industrial automation today?
The advancements shaping industrial automation today include the integration of advanced robotics, AI-driven control systems, and data-driven optimization techniques to enhance productivity, precision, and flexibility in manufacturing processes.
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Optimizing Packaging and Palletizing Operations
End-of-Line Packaging Automation
PASCO® designs and manufactures end-of-line automation systems that handle a wide range of packaging types, including bags, drums, cases and pails. Packaging automation replaces manual handling with consistent, repeatable performance at the end of the line.
Automating packaging improves throughput, reduces variability and keeps products moving through the line with greater consistency. PASCO systems are engineered to run reliably in real production environments where uptime matters.
Automated Palletizing
Automated palletizing systems from PASCO handle the final step of packaging by stacking finished products onto pallets at production speed. Automating palletizing improves efficiency, reduces manual labor and removes one of the most physically demanding tasks on the floor.
PASCO palletizing systems handle cases, boxes, bags, drums and other packaged products. Each system is engineered around the product, throughput and layout of the facility to deliver consistent palletizing performance.
The PASCO Approach
PASCO builds automation equipment as an original equipment manufacturer. Most critical components are manufactured in-house, keeping engineering, fabrication and system integration closely connected.
Customers work directly with the team that designs and builds their systems. That same team supports the equipment long after installation with parts and service when needed.
