Mixed case palletizing plays a key role in B2B distribution, particularly in industries like retail. It involves arranging products of different sizes and shapes on a pallet or cage cart, almost like playing a 3D Tetris game. As SKU requirements are unique to each order, building customized pallets with diverse products facilitates outbound delivery.

Challenges

In the fast-paced industrial landscape, retailers and manufacturers encounter challenges in managing greater product variety, handling increasing volumes, and meeting the rising demand for throughput. The growing expectations of supply chains also exert significant pressure, especially in B2B distribution.

Today, supply chains must accommodate the shifting needs of future demands. Future-proofing business operations during high seasons involve implementing strategies and technologies that allow for agile adjustments to inventory, workforce, and logistics to seamlessly respond to the demands of peak seasons.

Mixed case palletizing is such an effective way to manage diverse orders. Currently, manual labor remains the dominant method in most warehouses for mixed case palletizing. It is difficult for these warehouses to find and retain labor due to the physically demanding nature of this work. The repetitive heavy lifting poses significant safety and health risks. The demand for high throughput also leads to operational errors and inconsistent pallet builds, resulting in an unpredictable productivity level.

To overcome these challenges, companies are turning to automation solutions to not only optimize their operations but also ensure the sustainability of their businesses in the long term.

Methods to Automate Mixed Case Order Fulfillment

One of these automation solutions is using mixed case palletizing robots. There are three primary methods for automating the process from single-SKU stored pallets to mixed-SKU order pallets.

The first method focuses on a line-to-pallet solution. In controlled sequence mixed case palletizing, the system precomputes the optimal order pallet pattern and determines the feeding order of cases. This method involves layer-wise depalletizing, singulation, buffering & sequencing, sorting, and mixed case palletizing. While effective, it requires substantial infrastructure investment, occupies a large footprint, and may take years to turn profitable.

The second method involves random sequence (with buffer) mixed case palletizing. Using cameras mounted above the conveyor, the system can identify buffering cases in real time and choose the optimal one for optimized loads on order pallets. Combined with a vision-enabled robotic depalletizing system, this method streamlines the process of depalletizing, sorting, and mixed case palletizing.

The third method focuses on a pallet-to-pallet solution, featuring random sequence mixed case palletizing. This method can handle cases that come in a random sequence. With a more streamlined goods flow, a single robot handles both depalletizing and mixed case palletizing. You can watch the video to see this solution in action at a 3PL warehouse.

XYZ Robotics offers innovative robotic technologies for mixed case palletizing. Their system incorporates cutting-edge pallet planning and vision algorithms, enabling the robot to autonomously recognize cases and determine the best placement. This ensures stability and maximizes space utilization on the pallet. Notably, XYZ Robotics' proprietary technology was recognized as the Soft Prize Top 3 in the ICRA Stacking Challenge 2023.

Five Reasons to Use XYZ Robotics' Mixed Case Palletizing Robot

1-2 year ROI

Unlike traditional solutions relying on costly sequencers, XYZ Robotics' robot can handle various cases that come in a random sequence. This enables a faster return on investment within 1-2 years. Its modular design also allows businesses to start small and seamlessly scale up as their operations grow.

Improved ergonomics

The robotic solution reduces the risk of worker injuries associated with manual lifting and moving of heavy boxes, creating a safer work environment and allowing workers to focus on more complex tasks.

Space-saving

XYZ Robotics' robot is designed to be systematic, occupying only a pallet-sized footprint. Its intelligence saves valuable warehouse space compared to bulky sequencers.

Easy integration

The mixed case palletizing robot seamlessly integrates into existing systems. Its modular design allows for easy expansion, enabling businesses to efficiently handle diverse product mixes and varying throughput demands.

Increased accuracy and efficiency

With computer vision verification, XYZ Robotics' robot enhances precision and quality in handling multiple products. It minimizes product damage and picking errors, improving overall operational efficiency.

For more technical details, download the whitepaper or contact XYZ Robotics for a customized solution.