Palletizing and Depalletizing Stations – End-of-Line Automation

Name: ZW Automation Sp. z o.o.
Address: Fabryczna 10/BUD. A1, Wrocław, Poland, 53-609, PL
Telephone: +48 532 622 691

Palletizing and depalletizing stations by ZW Automation are comprehensive end-of-line automation solutions designed for efficiency, safety, and production flexibility. We engineer systems that take over the most repetitive and physically demanding tasks, ensuring stable 24/7 line operation.

Palletizing and depalletizing stations tailored to your production

Automation ensures uninterrupted production, enabling seamless order fulfillment regardless of product type, process complexity, or industry – from pharmaceuticals and chemicals, through FMCG, automotive, and logistics, to heavy industry. We work with solutions from leading brands (including FANUC and Siemens), but it is our integration expertise that determines the final success.

Your production without limits – what do you gain with our stations?

You gain a solution precisely tailored to your plant’s specific requirements. Palletizing and depalletizing stations are designed to seamlessly connect the beginning and end of the line into one reliable system. This ensures full process repeatability and improved ergonomics, relieving your team of the most demanding tasks.

Efficient handling of every load

Whether your product consists of lightweight cartons or heavy bulk packages, loads weighing up to 30 kg are handled with maximum precision. Pallets can reach heights of up to 2.5 m while maintaining perfect stability – even with the most complex stacking patterns.

Intelligence that drives performance

You receive a system in which automation manages interlayer sheets and enables layout adjustments to meet logistics requirements. Thanks to integrated vision systems, you gain:
• Continuous quality control: Every label and marking is verified in real time.
• Instant flexibility: Via intuitive HMI panels, operators can change product references without stopping production, eliminating downtime.

Performance you can rely on

The palletizer and depalletizer are ready for three-shift operation, ensuring 24/7 production continuity. With a cycle time of just 7.5 seconds and throughput exceeding 8 units per minute, bottlenecks become a thing of the past. Automation allows you to mitigate labor shortages and redeploy employees where their competencies truly add value.

Safe collaboration side by side

You gain both space and safety. By implementing our cobots, you introduce technology that works safely alongside operators without the need for heavy fencing. This is an ideal solution for dynamic production environments where every square meter counts. In practice, this means:

• Full freedom of movement: No permanent barriers mean smoother communication on the shop floor.
• Gentle precision: With “sense of touch” technology and repeatability of ±0.03 mm, even the most delicate products are handled safely.
• Certified safety: Advanced safety systems protect employees, allowing them to focus on supervision rather than heavy manual work.

Robotic technologies in end-of-line automation

At ZW Automation, we are not tied to a single manufacturer. We can propose the optimal technology or work with solutions specified by you. We cooperate with leading cobot manufacturers such as FANUC, OMRON, Yaskawa, Kawasaki, ABB, KUKA and others, enabling us to select the best technology for your requirements. We have experience integrating various PLC controllers (Siemens, Allen-Bradley, Mitsubishi Electric and others).

In one of our projects, we were among the first in Poland to implement the FANUC PalletTool® module.

This innovative software solution revolutionizes palletizing configuration management. FANUC PalletTool® allows the creation and editing of carton and interlayer stacking patterns without modifying the cobot’s main program. As a result, operators can independently add new product references, modify palletizing patterns, and adapt the process to current needs – while maintaining target efficiency and repeatability.

This tool shortens the time required to introduce new products and increases flexibility in multi-SKU production. Instead of waiting for a programmer to modify the cobot code, your team can easily manage palletizing configurations via an intuitive interface.

Although our experience with FANUC PalletTool® is unique, we offer similar functionalities for other cobot brands by using dedicated software modules or developing custom HMI interfaces for rapid reconfiguration.

Why choose robotic palletizing stations?

Tangible benefits

The visual impact of our work

Increased efficiency and reliability

Implementation of individual production targets – packing cycles from 10 seconds
Precise palletizing

Fast and accurate stacking of even complex patterns at speeds up to 8 cartons/min (single cartons).
Flexibility and reach

Handling multiple load types and stacking up to 2.5 m in height.
Continuous 24/7 operation

Three-shift readiness and easy reprogramming for new tasks.
Work satisfaction and ergonomics

Improved team comfort by relieving heavy manual tasks and providing intuitive operation.
Labor cost optimization

Efficient use of human resources through line automation.
Certified safety

Safe human-robot collaboration thanks to certified protection systems.
Space savings

Compact design enabling easy integration in limited production space.

Implementation stages of palletizing and depalletizing stations at ZW Automation

We begin every collaboration with an in-depth analysis of business objectives and industry-specific processes so that the designed automation becomes a true growth driver. We act as a partner to your technical department – refining existing concepts or developing proprietary solutions aligned with your production line architecture:

Design and integration – analysis and concept

We analyze your production processes, load types, performance requirements, and available space. After a site survey and infrastructure measurements, we develop an individual palletizer or depalletizer concept and define an initial automation strategy.
Technology selection – optimal robotic solutions

We analyze product dimensions, weight, and characteristics. We select the optimal robot arm – industrial or collaborative – along with dedicated gripper systems, vision systems, control components, and other technological subsystems to ensure maximum performance and reliability.
3D visualization – realistic workstation modeling

Using advanced CAD software such as Solid Edge, we create a realistic 3D model of your robotic cell. Simulations allow trajectory optimization and safety verification before installation.
Innovative software – advanced control systems

We implement advanced software solutions, including FANUC PalletTool®. We program robots, integrate them with PLC and higher-level systems (MES, ERP), and develop intuitive HMI interfaces enabling operators to independently add product references and modify palletizing patterns without stopping production.
Full execution and testing – from prefabrication to commissioning

We perform control cabinet prefabrication and mechanical assembly. We integrate the robot with PLC systems, configure wiring, install HMIs and safety systems, and conduct FAT and SAT tests to confirm production readiness.
Documentation and training – comprehensive knowledge transfer

We provide full technical documentation (CE declaration of conformity, test reports, operating manuals) and conduct comprehensive training for operators and engineers. We also provide warranty and post-warranty technical support.

Time to accelerate your production

We design and integrate stations that enhance productivity today and remain ready for tomorrow’s changes.

If you want palletizing and depalletizing to become a true production enabler, contact us. We offer a free site survey and a preliminary concept tailored to your industry requirements.

biuro@zwautomation.pl +48 532 622 691

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