Integrated Robotic Palletizing System
Transforming a six-year vision into an integrated end-of-line system
Omaha, Nebraska
2025
overview
Compact automation boosts output and quality
Equipment Used
Automatic bag hanger
Automatic bag labeling system
Automatic integrated stretch wrapper
Bag pick conveyor
Belt-over-belt bag flattener
Closing conveyor
Inline bag turner
Pacing conveyor
Robotic palletizer
Safety fencing
Staging conveyor
After six years of exploring automation, a long-standing manufacturer in the animal-health and feed-additive industry partnered with us to bring their vision to life. Their goal was to reduce labor, improve quality, and increase throughput to meet rising demand—all within their existing space.
We designed a compact, high-efficiency layout that combined an automatic bag hanger, pre-labeling system, robotic palletizer, and integrated automatic stretch wrapper, all working together as one streamlined process. The result is a connected, end-of-line system that delivers higher output, consistent quality, and long-term reliability.
IMPACT
Key results at a glance
Efficiency That Enables Growth
Throughput increased 30–35%, with peaks near 50%, moving over 2 million pounds in a single month. The system meets growing demand without adding shifts or floor space.
End-to-End Automation
Manual bag hanging, labeling, stacking, and wrapping were replaced with one automated line. Streamlining production from start to finish.
Safety and Retention
Automation reduced repetitive lifting and improved ergonomics, creating a safer, easier-to-run operation that supports long-term retention.
Approach
How we fixed the break
We began by developing two layout options that balanced footprint and automation level. After evaluating both, we selected a design that positioned the robotic palletizing cell close to the bagging scale, simplifying conveyance and reducing transfer time.
The original concept included a floor-mounted palletizer, but once we analyzed how completed pallets would move to a standalone stretch wrapper, a clear ROI emerged for integrating pallet conveyors and a fully automatic stretch wrapper into the same cell.
Tight space near the bagging scale required relocating column supports outside the automatic bag hanger footprint, and the path from the bag spout to the palletizer fencing left only inches of clearance from adjacent forklift aisles. Despite the compact footprint, the layout achieved full safety compliance and smooth operation.
The project also required custom stacking logic for square-bottom bags with overlap patterns and filled bags exceeding seven inches thick. The robot was programmed to build stable, consistent pallets that met exact specifications.
Installed and commissioned in late summer 2025, the system met every performance expectation. Today, operators oversee a continuous automated line—from pre-labeling to wrapped pallet—running safely, efficiently, and within the same footprint.
Through precise design, creative problem-solving, and collaboration, we transformed a six-year automation vision into a connected system where people, technology, and performance move as one.
