In the case of robot-based palletizing and secondary packing lines, the identification of the key issues should take place as early as at the planning and designing stage

Wikpol, the experiences of which in being an integrator includes almost three hundred implementations based on industrial robots, follows this very approach.

We begin working on a new line from precisely defining the requirements related to the project, such as:

The product parameters
The costs
The availability of materials and sub-assemblies
The space available
Production technology
Production conditions
Safety requirements
Transport logistics
Integration with other systems

The analysis of the issues mentioned above is sometimes extended by consultations with employees of the line, and with experts.

Based on the information collected, we are able to specify key problems and develop solutions, which will make it possible to optimize the production line. This information is our basis for configuring the line.


A correct configuration ensures the correct operation of the palletizing and secondary packaging line.

During this process, we specify (select) the key elements of the system, such as: the number and type of robots, cooperating devices, arranging the devices in the line, the transport system.

Then, we analyze the matters concerning the control system, the communication method between the line and external systems, off-line software, additional instrumentation (vision systems, sensors).


The best configuration of the line should ensure the parameters important to the user, such as:

Ensuring the right efficiency and work pace at the palletizing and seconadary packaging line involves coordinating precisely the movement of the robot with its cooperation with other devices.

The efficiency of the palletizing and secondary packaging line depends on various factors, such as: the speed of the robot’s movement, the robot’s cycle duration, the number and time of refittings, the number and duration of downtimes and failures, the number of shortages.

The costs
They include both the investment costs and the operational costs. The limitation of the costs is mainly affected by optimizing the processes and reducing the energy consumption. For this purpose, it is required to analyze the costs in detail in terms of identifying the areas where savings could be made, and specifying the costs which could be reduced.

Robot-based palletizing and secondary packaging lines are being designed to ensure the maximum safety to the people, equipment, and information. This is achieved through procedures of entering safely into the work areas, the robot’s safety system, by fencing off the line with switches certified for safety, safety sensors, safe data transmission protocols.


Robot-based palletizing and secondary packaging lines are integrated with other manufacturing systems and devices, such as transport systems, warehousing systems, and quality assurance systems.

In particular, these could be:

  • transport systems – the robots could pick up products from belt conveyors, other types of conveyors, and other transport devices
  • packaging machines – the robots could cooperate with packaging machines and other machines
  • wrapping machines, labelling machines
  • warehousing systems – the robots can pick up products directly from pallet warehouses, or from shelves
  • vision systems – the robots can use visual systems to identify products, position or arrange before palletizing or packaging
  • quality control systems – the robots could cooperate with quality control systems to inspect the quality of the products during the palletizing and packaging process,
  • production control systems – the robots can receive data on the production schedule and direct the palletizing and packaging processes according to this schedule
  • logistic systems
  • the robots can use logistic systems, such as warehousing software, in order to receive data on the product inventory and plan the palletizing and packaging processes

Integration may involve various issues, among which the most serious are:

The compatibility of the systems
Different production systems may have different communication protocols, which makes it difficult to exchange data between them. It may be necessary to deploy special software or data converters.

Production Schedule
The robot-based palletizing and secondary packaging lines must be synchronized with other manufacturing lines to ensure effective production, avoid downtimes, and maximize the use of resources.

Technical Support
To integrate different production systems requires knowledge and experience in the field of automation, robotics, IT. Wikpol’s specialists have completed several hundred effective implementations.


The robot-based palletizing and packaging lines meet the requirements of the binding regulations and standards concerning safety, environment, and quality, including the machine directive, ATEX (for devices employed within any zones endangered with explosions).

Quality management system Wikpol matches the norms ISO 9001:2015.


The correct operation is one pre-condition for the palletizing and secondary packaging line to work reliably. The guidelines developed by Wikpol, addressed to the operation maintenance services, are intended to maintain smooth, possibly failure-free operation of the systems, as well as to minimize the time of stoppages. Adhering to the recommendations concerning timely inspections, regular maintenance operations, calibrations and replacements of parts is a pre-condition for operating the line effectively over many years.

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