Palletizing

Palletizing - key technology for optimized logistics chains

Modern palletizing solutions increase efficiency, reduce costs and increase occupational safety in intralogistics

Modern automated palletizing systems are up to five times faster than manual palletizing. An investment that pays off. After all, precise Palletizings are the basis for smooth logistics processes and minimize transport damage. At a time of rising personnel costs and growing logistics requirements, the right Palletizings is crucial for the profitability and success of the entire supply chain.

Palletizing is more than just simple stacking

Palletizing refers to the process in which products, goods or containers are systematically arranged on load carriers. Its significance therefore goes far beyond mere stacking. Modern palletizing systems work with maximum precision and speed, minimize transport damage and increase occupational safety. The material flow is optimized and flexible solutions enable quick adjustments to be made for changing product formats.

An efficient palletizing system has to overcome various challenges: different product sizes and shapes, changing stacking patterns, load stability during transport and optimal use of space. Companies are faced with a choice between manual, semi-automatic and fully automatic solutions – depending on throughput, product variety and investment budget.

Which processes are used for palletizing?

Palletizing is all about positioning products on pallets safely, efficiently and in a space-saving manner. Different technical approaches are used depending on the type of product, weight, throughput and space available. A basic distinction is made between the push, clamp, push-over and pull methods, each of which offers specific advantages in terms of product stability and handling.

At BERNING, the focus is not on classic mechanical processes, but on flexible, robot-assisted palletizing solutions.

With the help of these systems, individual products or containers can be placed or set down on the pallet precisely, with repeat accuracy and adaptable to different formats and packaging units.

Thanks to modern, digital Control technologies and individually programmable motion sequences, our robots can handle a wide variety of product shapes, create variable layer patterns and adapt quickly to new requirements. This results in palletizing solutions that are efficient, future-proof and space-saving.

The advantages of Berning palletizing technology at a glance:

  • Precise and gentle handling of individual products
  • High flexibility thanks to freely programmable robot movements
  • Space-saving design and easy integration into existing lines
  • Efficient processes with end-to-end digital control
  • Future-proof technology for changing product and packaging requirements

Berning offers modern palletizing solutions that simplify processes, ensure quality and make a significant contribution to the automation and digitalization of the production chain.

Testing at BERNING: Customized solutions for complex requirements

Automation has fundamentally changed this process. According to recent surveys, 75% of companies already use robotics, particularly for palletizing and depalletizing [1]. This development is no coincidence, as automated systems offer decisive advantages:

AspectManual PalletizingsAutomated Palletizings
PrecisionFluctuating, person-dependentConstantly high
Occupational safetyRisk due to heavy liftingSignificantly reduced risk of injury
Personnel costsHigh, several employees requiredLow, minimal personnel requirements
FlexibilityGood for small series and special formatsHigh, requires programming
AvailabilityDependent on personnel deploymentAlmost 24/7 possible
Energy consumptionLowModerate, up to 70 % lower for electric systems than for pneumatic systems

Modern electric palletizing systems consume up to 70 percent less energy than their pneumatic alternatives. This not only reduces operating costs, but also improves the company’s carbon footprint [2]. At the same time, they meet the requirements of Industry 5.0 with their fully electric drive systems.

Thanks to modern interfaces, integration into existing production lines is becoming increasingly simple. Flexible systems can be adapted to different pallet sizes and conveyor types, which increases investment security [2].

Legal framework

According to the European Pallet Association (EPAL), the new EU deforestation regulation has no impact on the logistics processes of suppliers and recipients of goods or on the exchange of EPAL pallets [3]. The existing processes can continue unchanged, which means planning security for companies.

Nevertheless, companies should keep an eye on developments in the area of the European Packaging Regulation (PPWR). From 2026, this will place new requirements on Packagings and thus indirectly also on Palletizings [4].

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BERNING Maschinenfabrik: Innovative palletizing solutions from a single source

BERNING Maschinenfabrik specializes in tailor-made palletizing solutions that are precisely tailored to the customer’s needs. The company combines many years of experience with innovative technology and offers a wide range of palletizing systems.

Core competencies of BERNING palletizing technology:

  • Cardboard Palletizings
    Precise and safe stacking of cardboard boxes of different formats and weights
  • Palletizings for containers
    Special solutions for Bottles and other containers with optimum stacking stability
  • Bag Palletizing
    Gentle and safe Palletizing of bags with different filling media
  • Multi-layer Palletizings
    Complex stacking patterns with maximum stability for safe transport
  • Integration of external palletizing schemes
    Flexible adaptation to customer-specific layout plans and stacking instructions
  • Layer pad handling
    Automatic insertion of layer pads made of kraft paper, cardboard or plastic for optimum stability

Thanks to their modular design, BERNING systems can be flexibly adapted to different production environments and growing requirements. Each system is individually designed and can be expanded or modified at a later date.

A typical project process at BERNING is as follows:

  1. Requirements analysis
    Precise recording of the palletizing task, product properties and environmental conditions
  2. Concept development
    Development of customized solutions, taking into account all technical and economic aspects
  3. Detailed planning
    Precise elaboration of all components and interfaces
  4. Production
    Production of mechanical and electronic components to the highest quality standards
  5. Installation and commissioning
    Professional assembly and setup on site at the customer’s premises
  6. Training and support
    Comprehensive instruction of operating personnel and long-term support

Why efficient Palletizings become a competitive advantage

In an increasingly competitive market environment, the efficiency of the logistics chain is decisive for economic success. Modern palletizing systems make a decisive contribution here

1.

Economic advantages

  • Reduction of personnel costs through automation
  • Minimization of transport damage through precise stacking
  • Higher throughput rates and improved system utilization
  • Lower energy consumption thanks to modern electrical systems
  • Flexibility with changing product formats
2.

Technical advantages:

  • Consistent quality of Palletizings regardless of shift or time of day
  • Precise positioning for optimum use of space
  • Integrated quality control to prevent errors
  • Improved occupational safety due to elimination of manual lifting activities
  • Complete integration into higher-level control systems

Frequently asked questions about Palletizings (FAQ)

How much does an automated Palletizing system cost?

The investment costs vary depending on throughput, complexity and degree of automation. The total cost calculation, taking into account the savings in personnel costs, reduced transport damage and higher throughput rates, is decisive for the profitability analysis. Modern financing models such as leasing or pay-per-use also make the investment attractive for smaller companies.

Modern palletizing systems are designed for fast product changeovers. Thanks to intuitive user interfaces and stored product profiles, changeover times can be reduced to just a few minutes. Tool changes, such as for grippers or suction cups, can also be carried out quickly and often automatically. This means that different product sizes or shapes can be processed without long downtimes.

Most systems store hundreds of different stacking patterns and product configurations that can be called up quickly when required. Some particularly advanced systems even automatically detect product characteristics and adjust the Palletizings, including the appropriate tool, on their own.

Electric palletizing systems consume up to 70 percent less energy than their pneumatic alternatives [4]. This not only reduces operating costs, but also improves the company’s carbon footprint.

3.

Future prospects: Where is Palletizings heading?

Palletizing technology is a dynamic field with continuous innovations:

  1. Collaborative robotics
    New safety concepts enable humans and Palletizing robots to work together directly without the need for separating protective devices.
  2. Artificial intelligence
    Self-learning systems optimize stacking patterns and automatically adapt to changing product properties.
  3. Autonomous vehicles
    The combination of palletizing systems and driverless transport systems creates end-to-end, automated material flow solutions.
  4. Digital twins
    Virtual images of real palletizing systems enable precise simulation and optimization.
  5. Sustainable materials
    New developments in interlayers and securing materials reduce the ecological footprint.
Conclusion

Tailor-made palletizing solutions are the key to success.

Efficient Palletizings is more than just stacking products. It is a decisive factor for optimized logistics chains. With the right palletizing systems, companies can increase their productivity, reduce costs and increase occupational safety.

BERNING Maschinenfabrik offers customized solutions that are precisely tailored to the customer’s requirements – from palletizing cartons, packs and bags to complex, multi-layer palletizing patterns with automatic interlayer insertion. The modular systems grow with the requirements and can be flexibly adapted to changing production conditions.

At a time of rising personnel costs and growing logistical challenges, investing in modern palletizing technology is increasingly becoming a competitive advantage. Companies that rely on innovative palletizing solutions now will secure a leading position in their market.

Sources

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