Cross Pallet Packer to Save Up to 40% of Warehouse Space
The logistics branch of a well-known high fashion and luxury goods brand having an office in Switzerland turned to Siscodata for its need to create piles of crossed wooden pallets (by crossing "up/down") in order to reduce, during the transport, the occupied space of more than 40%.
Siscodata has realized an innovative solution integrating a Comau robot, a gripper and other components designed ad hoc to automate this operation which, previously, was carried out by hand by different operators and which was very tiring considering the weight of 15 Kg to pallets and the number of pallets handled.
The type of pallet managed, in this case, is EURO 1200 L x 800 W x 150 H mm with a maximum height of the stacks (including the wooden platform) of about 2000 mm max.
The machine detects the pallets passing on a free roller conveyor in exit and, through a sensor system, the system recognizes if it is a pallet of material, that is sent forward, or if it is a "pallet of pallets", which is instead processed and crossed "up/down".
How to optimize pallet stacking and reduce warehouse space
Siscodata's Cross Pallet Packer is a robotic automation system designed to solve one of the most common inefficiencies in wooden pallet logistics: excessive space consumption during pallet stack transport and storage.
By crossing pallets "up/down" through a robotic gripper system, Siscodata's technology can reduce the occupied space of stacked wooden pallets by up to 40% — directly cutting the number of handling movements, transport runs, and storage footprint required for the same volume of goods.
This solution is particularly valuable for high-volume logistics and e-commerce distribution operators that manage large quantities of EURO pallets (1200 x 800 x 150 mm) and need to reduce internal handling operations, previously carried out manually and prone to fatigue and inefficiency.
The system has been in continuous operation for over 5 years in an active logistics warehouse, automating a process that was previously subcontracted or performed by hand — proof of a mature, field-tested industrial solution rather than a prototype.
Frequently asked questions
Is there a way to reduce the space taken up by pallet stacks during transport?
Yes. Crossing pallets in an "up/down" configuration — as implemented by Siscodata's Cross Pallet Packer — can reduce the space occupied by stacked wooden pallets by up to 40%, without changing the pallet type or dimensions.
What kind of companies benefit most from cross-pallet stacking automation?
Logistics operators, distribution centers, and e-commerce fulfillment companies that handle large volumes of pallet movements benefit most, since reducing space per stack directly reduces the number of transport and handling operations needed.
How reliable is robotic cross-pallet stacking in real industrial use?
Siscodata's system has operated continuously for more than 5 years in a live logistics facility, automating a task that was previously done manually.
FAQ
Frequently asked questions
1 / Is there a way to reduce the space taken up by pallet stacks during transport?
Yes. Crossing pallets in an "up/down" configuration — as implemented by Siscodata's Cross Pallet Packer — can reduce the space occupied by stacked wooden pallets by up to 40%, without changing the pallet type or dimensions.
2 / What kind of companies benefit most from cross-pallet stacking automation?
Logistics operators, distribution centers, and e-commerce fulfillment companies that handle large volumes of pallet movements benefit most, since reducing space per stack directly reduces the number of transport and handling operations needed.
3 / How reliable is robotic cross-pallet stacking in real industrial use?
Siscodata's system has operated continuously for more than 5 years in a live logistics facility, automating a task that was previously done manually.
4 / Does the robot check for safety before stacking?
Yes. The robot checks the height of the pallet stack using a laser triangulation sensor before each cycle, to avoid collisions between the gripper and any pallet that may have been added manually.
3 / What robot brand does Siscodata use for this application?
The Cross Pallet Packer integrates a Comau (or Fanuc / Kuka / ABB) industrial robot combined with a custom-designed gripper and additional automation components engineered specifically for pallet cross-stacking.
The robot begins its cycle by checking the height of the pallet through a laser triangulation sensor to avoid impacts between the gripper and a possible last pallet added by hand.
In the output part there are 2 roller conveyors in cascade: the first serves as a basis for the cross stack erection, while the second serves as an output buffer.
Thanks to this solution, the customer has been abled to bring this process inside the production site, while previously was subcontracted, and also to reduce the laborious work to its operators.