Granta Automation Palletiser News

Future-Proofing Your Manufacturing Line with Robotic Palletising

Posted on July 11, 2025 by Granta

Manufacturing is evolving at a faster pace than ever before. The combined pressure of global supply chain disruptions, increasing product complexity, labour shortages, and the relentless demand for faster throughput is pushing manufacturers toward smarter, more agile production strategies. In this high-stakes environment, companies that continue to rely on manual, outdated processes are at risk of falling irreversibly behind.

One area that has seen a rapid and impactful shift is end-of-line automation—specifically robotic palletising. Once seen as a luxury investment for large operations, robotic palletising is now a practical, scalable solution that delivers immediate ROI while paving the way for long-term competitiveness.

In this article, we’ll examine why robotic palletising is more than a tactical upgrade—it’s a strategic necessity. We’ll look at the rising demand for automation across the sector, how robotic palletising systems are designed for seamless integration and how automation equips manufacturers to adapt and thrive in a rapidly changing industrial landscape.

The Growing Demand for Automation in Manufacturing

Over the last decade, automation has shifted from being a tool of efficiency to a lifeline for continuity and growth. In a world where product mixes change rapidly, customer expectations for shorter lead times intensify, and access to skilled labour is increasingly constrained, manufacturers are being forced to rethink how they structure their production lines.

Robotic palletising offers a powerful solution to many of these challenges. It eliminates manual handling errors, reduces workplace injuries, enhances consistency in pallet formation, and can operate continuously with minimal supervision. With many plants operating multiple shifts to meet demand, having a system that doesn’t fatigue, doesn’t require breaks, and performs with unwavering precision becomes a clear competitive advantage.

Beyond efficiency, automation is becoming a prerequisite for meeting customer compliance requirements. Retailers and distributors are increasingly setting stricter standards for pallet quality, labelling accuracy, and load stability. Robotic palletisers help ensure that every pallet leaving your facility meets these standards without exception.

Global spending on industrial robots in the packaging and palletising sector has increased year on year, with SMEs now representing one of the fastest-growing segments in automation adoption. The message is clear: automation is no longer confined to mega-factories—it’s a vital asset for operations of every size.

Seamless Integration: From Legacy to Leading-Edge

One of the lingering myths around robotic palletising is that it’s disruptive to implement. In reality, modern palletising systems are designed to integrate quickly and cleanly with existing infrastructure—whether you’re working with legacy machinery or the latest production technology.

At the heart of this easy integration is system design. Robotic cells are now built with flexibility in mind: compact footprints, adjustable infeed and outfeed conveyor heights, and custom end-of-arm tooling ensure that they can slot into existing production lines with minimal reconfiguration. Many systems can be installed and commissioned within a matter of days, drastically reducing any potential downtime.

Communication between systems has also become significantly more seamless. Robotic palletisers can now ‘talk’ to upstream equipment (such as case erectors or labellers) and downstream logistics systems (like AGVs or stretch wrappers) with ease. This connectivity not only ensures smooth operation but also opens the door to real-time process synchronisation.

Furthermore, user-friendly interfaces such as Granta Automation’s easy programming software have replaced the complicated programming environments of the past. Today’s HMIs are designed for operators, not programmers. That means a shift supervisor can teach the robot a new product pattern or diagnose a fault in minutes—without calling in an engineer.

Agility Through Automation: Thriving Amid Change

In today’s climate, adaptability is more than a strategic advantage—it’s a survival skill. Manufacturers are expected to pivot quickly in response to everything from market fluctuations to global crises. Whether it’s a sudden change in packaging regulations, an urgent shift in product mix, or a rapid scale-up due to new contracts, flexibility is key.

Robotic palletising gives manufacturers the ability to respond without overhauling their entire production line. For example, changes in SKU dimensions can managed simply with the easy programming software from Granta Automation. Anyone can reprogram the palletiser for new product sizes or stack patterns within just a matter of minute. A surge in output can be absorbed by running the robot longer hours without compromising accuracy. Even layout reconfigurations—such as moving a line to accommodate a new machine—can be achieved more easily when your palletising is modular and mobile.

In addition, automation helps companies remain compliant and forward-thinking. As environmental and sustainability regulations tighten, companies are being asked to use lighter, more recyclable materials—which often behave differently during stacking. Robotic palletisers equipped with smart sensors and adaptive grippers can handle these delicate loads better than manual operators or older fixed automation systems.

And finally, consider the impact on your workforce. While automation reduces the need for repetitive manual labour, it also elevates the roles of existing staff. Operators become system supervisors, responsible for optimisation and oversight, rather than physical execution. This shift not only improves morale and retention but also fosters a culture of continuous improvement.

Conclusion: A Strategic Imperative, Not a Technical Upgrade

As the manufacturing landscape becomes more complex and demanding, the need for smart, scalable solutions is undeniable. Robotic palletising addresses immediate operational pressures while delivering a foundation for long-term agility and scalable growth.

It’s more than a productivity tool—it’s a strategic asset that empowers manufacturers to future-proof their operations. From seamless integration to adaptable performance, robotic palletising is transforming how factories run, how teams work, and how businesses compete.

For those ready to lead, the time to automate is now. Contact us today for a quote on 01223 499488 or email helpline@granta-automation.co.uk, and discover how automated palletising can revolutionise your manufacturing process.

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Why Operational Efficiency Is the #1 Competitive Advantage in Manufacturing

Posted on July 10, 2025 by Granta

In an industry defined by margins, milliseconds, and materials, efficiency is no longer a best practice — it’s the basis of survival.

For decades, manufacturers have sought competitive advantages in scale, location, and labour cost. But the 21st century has shifted the goalposts. In today’s hyper-competitive, globally connected, and unpredictably disrupted markets, the only sustainable edge is operational efficiency.

The most successful manufacturers don’t necessarily spend more. They don’t always own the biggest plants or employ the largest workforces. But what they do have — what consistently sets them apart — is the ability to do more with less, faster, and with higher precision.

Why Efficiency Matters More Than Ever

In 2025, the pressures on manufacturers are unprecedented:

Global volatility: Supply chain shocks, energy fluctuations, geopolitical instability, and pandemics have forced a rethink of just-in-time logistics and offshore dependencies.
Labour shortages: Skilled trades and experienced operators are increasingly scarce. Competition for talent is fierce. Retention is fragile.
Customisation demand: Clients expect shorter lead times, greater flexibility, and personalised products — without cost increases.
Sustainability mandates: ESG pressures are driving efficiency not just as a financial necessity, but as an ethical imperative.

Every inefficiency — a slow tool change, an outdated scheduling system, a non-integrated data source — represents a silent tax on profitability. And the compounding cost of this inefficiency is enormous.

It is estimated that the average manufacturing plant operates at just 60-70% of its maximum efficiency. The remaining 30-40% is opportunity — or, for the laggards, existential risk.

What the Best Manufacturers Do Differently

Leading manufacturers treat efficiency not as a KPI, but as a company-wide philosophy. Here’s what sets them apart:

1. Process Discipline at Every Level

Top-performing plants have one thing in common: standardised, repeatable processes that leave little to chance. Every task, from raw material intake to final packaging, is documented, time-stamped, and monitored. Variability is identified and eliminated.

But standardisation doesn’t mean rigidity. These manufacturers build flexibility into their operations, allowing them to shift between products or production volumes quickly, without losing control over cost or quality.

2. Empowered Frontline Teams

Modern efficiency isn’t driven solely from the boardroom — it’s shaped by the people on the floor. Operators in high-efficiency environments are trained to recognise waste, stop production when issues arise, and contribute to process improvements.

This is where Lean meets culture: systems like daily Gemba walks, visual dashboards, and autonomous maintenance empower teams to act fast and solve problems early.

3. Data-Driven Decision Making

Gut feel no longer cuts it. High performers capture real-time data from machines, lines, operators, and sensors — and use it to guide decisions. KPIs are tracked in real time, not weekly. Downtime is analysed within minutes, not after shift reports. And continuous improvement becomes measurable, not anecdotal.

A plant that knows its OEE in real-time — and can pinpoint the reason for each efficiency loss — is already miles ahead.

Technology as a Force Multiplier

Efficiency no longer means “doing the same things faster.” It means redefining how things are done — often with the help of technology.

Industry 4.0: Turning Insight into Output

The fusion of operational technology (OT) and information technology (IT) has unlocked the smart factory.

IoT sensors now provide second-by-second feedback from equipment — enabling predictive maintenance and eliminating unplanned downtime.
AI and machine learning crunch production data to find hidden inefficiencies, optimise scheduling, and forecast machine failure.
Digital twins allow manufacturers to model new production layouts or process changes without disrupting operations.
Cloud-based MES systems integrate ERP, supply chain, and shop floor systems — creating a seamless, real-time view of operations.
Automation solutions such as robotic palletisers streamline repetitive end-of-line tasks, freeing up skilled labour and reducing cycle time — a small change that can yield significant efficiency gains over thousands of shifts.

Lean + Tech = Smart Efficiency

Technology isn’t a replacement for Lean thinking — it’s an amplifier. Lean gives manufacturers the discipline and mindset to eliminate waste. Technology makes that discipline scalable and repeatable. It enables leaders to:

See deviations as they happen
Identify trends across shifts or sites
Capture tribal knowledge before it walks out the door
Simulate changes before investing capital

How to Optimise Production Processes: A Proven Framework

Whether you’re running a single plant or managing operations across global sites, the journey toward efficiency follows a clear trajectory.

Step 1: Baseline Performance

Begin with visibility. What is your current OEE? How much downtime is truly unplanned? Where are materials wasted or labour underutilised?

Use value stream mapping, spaghetti diagrams, and time-motion studies. Establish a data-driven baseline before rushing into changes.

Step 2: Prioritise Bottlenecks and High-Cost Areas

You can’t fix everything at once. Focus on areas that impact throughput, scrap, energy usage, or machine uptime. Identify “hidden factories” — workarounds or rework loops that silently erode productivity.

Prioritisation tools like Pareto analysis and 5 Whys help focus limited resources.

Step 3: Digitise for Insight

Install monitoring systems on legacy equipment. Tie manual stations into digital forms. Start with low-code platforms or plug-and-play IIoT devices. Digitisation doesn’t have to mean full automation — it just means turning data into action.

Ensure KPIs are visible to everyone. Operators should see how their work contributes to daily goals.

Step 4: Standardise Workflows and Train Relentlessly

Introduce standard operating procedures (SOPs) for all high-variability tasks. Invest in cross-training. Use visual work instructions, QR-coded manuals, and digital checklists to reduce errors and increase consistency.

Make training continuous — not just for onboarding.

Step 5: Establish a Culture of Kaisen

Efficiency is a daily habit, not a one-off project. Encourage feedback, reward improvement suggestions, and close the loop by implementing operator-driven ideas.

Regular performance reviews, weekly improvement huddles, and recognition programs go a long way in sustaining momentum.

From Efficiency to Market Leadership

Consider this: two manufacturers produce the same product. One delivers it in 2 days with a 1% defect rate. The other in 5 days, with 4% defects, at 8% higher cost.

Which one will win the next contract? Which one will scale profitably? Which one will adapt to the next supply chain shock?

The most efficient manufacturers don’t just produce better — they compete better. They respond faster to change. They reinvest savings into innovation. And they attract customers who value reliability and agility.

Efficiency is the ultimate competitive advantage. It touches everything: output, cost, quality, morale, and customer satisfaction. Operational efficiency is not a destination — it’s a discipline. In today’s market, it’s also a differentiator that cannot be faked or fast-tracked. For operations leaders and plant managers, the mandate is clear: move faster, work smarter, reduce waste, and empower people. The tools are ready. The frameworks are proven. And the winners will be those who treat efficiency not as a quarterly target — but as the foundation for long-term dominance.

If you would like to know more about the Granta palletising systems or AMR/AGV systems and the efficiencies they can bring, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk. We will be very happy to help.

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Posted in AGVs, AMRs, Auto Palletiser, Automated Container Unloading, Automated Palletising, Bag Palletiser, Box Palletiser, Cobot Palletiser, Compact Palletiser, Container Destuffing, Container Destuffing Palletising, Container Unloading Palletising, Depalletising, Modular Palletiser, Palletiser, Palletiser - Granta Palletiser System, Palletising, Robotic Palletiser, Robotic Palletising, Small Palletiser | Tagged manufacturing efficiency, operational efficiency. | Comments Off

What Are Gemba Walks — And Why They Matter Now More Than Ever

Posted on July 9, 2025 by Granta

In high-performing manufacturing environments, true operational insight doesn’t come from a dashboard—it comes from the floor. That’s the principle behind Gemba walks, a foundational Lean practice that has become increasingly vital in modern industrial operations.

The Meaning Behind “Gemba”

Gemba is a Japanese term meaning “the real place.” In a manufacturing context, this is the shop floor—the production line, the maintenance bay, the loading dock. It’s where products are made, value is created, and problems actually occur.

A Gemba walk is a structured, purposeful walk through the workplace by leaders, engineers, or supervisors to observe operations firsthand. It is not a tour. It is not a performance evaluation. It is a deliberate exercise in seeing, listening, and understanding.

The Purpose of Gemba Walks: Why They’re More Than Just a Walkaround

In manufacturing, the fastest path to inefficiency is decision-making disconnected from reality. Gemba walks address this by enabling leaders to:

Observe actual processes in real-time, not filtered through reports or screens
Engage directly with frontline employees to gain unfiltered insights
Identify waste, friction, and inefficiencies that go unnoticed in standard metrics
Reinforce a culture of continuous improvement by demonstrating leadership involvement

“Go see, ask why, show respect.” — This Lean mantra captures the spirit of a Gemba walk. It’s not about managing from a distance; it’s about leading from proximity.

How Effective Gemba Walks Work

While every Gemba walk will differ based on goals, the best are structured, intentional, and recurring. Here’s how it’s typically done:

Define the Focus
Don’t wander aimlessly. Choose an objective—safety, quality, downtime, changeover efficiency, standard work adherence, etc.
Go to the Gemba
Visit the site where value is created. This could be the shop floor, warehouse, machine station, or even a digital operations room.
Observe Processes, Not Just People
Watch the workflow. Is there motion waste? Is material staging efficient? Are operators forced to wait or rework?
Engage Operators Thoughtfully
Speak with team members. Ask open-ended questions like:
- “What gets in the way of doing your job more efficiently?”
- “If you could change one thing in this process, what would it be?”
- “What’s the most common issue you see here?”

The goal isn’t to criticize—but to listen without judgement.

Document Observations, Not Just Problems
Record everything: observed delays, excessive walking, tool searches, unclear SOPs, inventory pile-ups. But also document what’s working well.
Follow Up and Close the Loop
A Gemba walk without action is worse than no walk at all. Reflect, analyse root causes, and most importantly—return to those involved with feedback or next steps.

The Strategic Value of Gemba Walks

While Gemba walks may seem tactical, their strategic impact is profound:

They surface hidden inefficiencies—like waiting time, excess motion, and communication delays—that traditional KPIs often miss.
They help bridge the gap between leadership and execution, building trust across all levels of the organization.
They reinforce accountability and ownership at the shop-floor level.
They reveal misalignments between standard operating procedures (SOPs) and real-world practices—giving you opportunities to revise, retrain, or improve.

In high-performance plants, Gemba walks are a daily discipline—not a quarterly exercise. They serve as the bedrock for Lean transformation, operator engagement, and long-term cultural change.

Gemba Walks in the Digital Age

Today’s smart factories are integrating digital tools into traditional Gemba walks:

Mobile devices allow leaders to log issues or photos on the spot.
Real-time dashboards enable comparison between what’s observed and what’s being reported.
Digital Gemba tools let distributed teams conduct hybrid walk-throughs, combining on-site and remote observation with virtual collaboration.

But even with these tools, the principle remains unchanged: go to where the value is created, and see for yourself.

In a world where leadership is often detached from day-to-day operations, Gemba walks are a simple, powerful way to stay grounded in reality. They drive alignment. They uncover what spreadsheets can’t. And they turn leadership into a visible, respected force for positive change. In the pursuit of operational excellence, Gemba walks are no longer optional. They are essential.

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How Fast Can My Cobot Run Without Guarding?

Posted on June 18, 2025 by Granta

When integrating collaborative robots (cobots) into production lines, a common and crucial question arises: How fast can my cobot safely operate without physical guarding? The answer hinges on comprehensive risk assessments, adherence to industry standards such as ISO 10218-2 and ISO/TS 15066, and the implementation of appropriate safety measures.

Understanding Safety Requirements

ISO 10218-2, the international standard for industrial robots, does not require physical guarding for cobots but mandates a thorough risk assessment to guarantee safe operation. Cobots come equipped with inherent safety features—such as force and speed limiting controls—that can permit unguarded operation, but only when specific conditions are met.

ISO/TS 15066 complements this by defining precise force and pressure thresholds to ensure safe human-robot interaction. These limits vary depending on the body part involved, recognizing that some areas are more vulnerable to injury:

Shoulder impact: up to 150 Newtons (N)
Forearm impact: approximately 50 N
Head or hand impact: as low as 10–20 N due to increased sensitivity

For a cobot operating in collaborative mode, staying within these force limits is essential to prevent injury.

Running a Cobot Without Guarding

The most straightforward approach to running a cobot without physical guarding is to limit its speed, ensuring that the forces exerted remain within safe boundaries.

Typical industrial robots operate at speeds up to 2,000 mm/s in non-collaborative modes.
In collaborative mode, ISO/TS 15066 recommends speeds of 250 mm/s (0.25 m/s) or less to meet safe force requirements, although a risk assessment might permit higher speeds depending on the specific application.
Practically, if a robot normally processes around 10 boxes per minute at full speed, running in collaborative mode might reduce throughput to roughly 1–1.5 boxes per minute, depending on risk factors and payload.

This speed reduction approach ensures compliance without the necessity for additional physical safety equipment. However, if faster operation is needed, other safety solutions must be explored.

Running Faster Without Physical Guarding

To increase operating speeds without resorting to traditional guarding, manufacturers can integrate safety technologies such as light curtains and area scanners:

Light Curtains act as virtual safety barriers, automatically slowing or stopping the cobot when someone crosses the beam. Proper safety distance calculations are crucial to maintain worker safety.
Area Scanners detect personnel approaching the work cell and dynamically adjust cobot speed or halt operations as needed. Their installation requires precise positioning and compliance with Performance Level d (PLd) safety standards.

While these technologies eliminate the need for solid physical barriers, they add complexity to system layout, safety distance management, and control programming.

Final Thoughts

A cobot can indeed operate without guarding, but with important limitations:

In fully collaborative mode, the cobot’s speed must be significantly reduced to comply with ISO/TS 15066 force limits.
Light curtains and area scanners provide options for higher speeds without physical guarding but require precise safety measures.
Comprehensive risk assessments are essential to balance safety, productivity, and regulatory compliance.

By carefully evaluating your specific application and following the guidelines set by ISO 10218-2 and ISO/TS 15066, you can achieve an optimal balance between efficiency and safety. If you’d like to discuss how Granta Automation can support your cobot integration contact us on 01223 499488 or helpline@granta-automation.co.uk.

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Manual Palletising vs Automated Palletising: Understanding the True Cost

Posted on June 18, 2025 by Granta

In today’s ever competitive manufacturing and logistics sectors, the efficiency and reliability of palletising processes directly influence your bottom line, operational safety, and overall supply chain resilience. At Granta Automation, we know that the choice between manual and automated palletising isn’t merely a question of upfront investment—it’s a strategic decision that impacts your long-term productivity, workforce wellbeing, and business scalability.

The Hidden, Often Overlooked Costs of Manual Palletising

While manual palletising is still widespread across many industries, largely due to its lower initial capital requirements and perceived operational flexibility, these short-term savings often conceal significant and escalating hidden costs:

1. Escalating Labour Expenses:
Manual palletising requires a consistent workforce, often involving physically demanding tasks that can lead to fatigue and injury. With the UK’s National Living Wage increase to £12.21 per hour for workers aged 21 and over, and £10.00 per hour for those aged 18 to 20, along with the recent increase in employers NICs, labour costs are rising significantly. This escalation in wages, coupled with overtime, training, and benefits, significantly increases operational expenses.

2. High Risk of Injury and Absenteeism:
Repetitive lifting, awkward postures, and strenuous manual handling dramatically increase the likelihood of musculoskeletal disorders and workplace injuries. According to the UK’s Health and Safety Executive (HSE), manual handling incidents cause thousands of lost workdays annually, leading to both productivity declines and increased compensation and insurance premiums.

3. Inconsistent Throughput and Quality:
Human operators, however skilled, are subject to fatigue and variability. This can lead to bottlenecks, inconsistent pallet quality, increased product damage, and downstream disruptions that negatively affect customer satisfaction and operational flow.

4. Limited Flexibility and Scalability:
Scaling manual operations in response to fluctuating demand is cumbersome and expensive. Hiring and training new workers or managing overtime leads to delays and ballooning operational costs that limit your competitiveness.

Automated Palletising: A Strategic Investment in Efficiency and Safety

Though automated palletising solutions often require a higher upfront capital investment, the long-term benefits and return on investment are compelling and measurable. Alternatively, you can hire a palletiser for as little as £2.19 per hour, providing a flexible and cost-effective option for businesses not yet ready to invest in full automation.

1. Significant Labour Cost Reduction:
Automation dramatically reduces the reliance on manual labour for palletising tasks. This not only cuts labour expenses but allows your workforce to be redeployed to higher-value roles, improving overall operational efficiency and employee satisfaction.

2. Enhanced Throughput and Consistency:
Automated palletisers run continuously and deliver uniform, high-quality pallet stacks at a steady, optimised pace. This consistency ensures smoother warehouse operations, reduces product damage, and improves fulfilment accuracy—key drivers of customer loyalty and reduced waste.

3. Improved Workplace Safety and Reduced Injury Costs:
By eliminating repetitive manual handling, automation lowers the risk of injury significantly. This translates into fewer lost workdays, lower insurance costs, and an overall healthier workforce, fostering a positive working environment and reducing costly absenteeism.

4. Scalable and Flexible Systems for Future Growth:
Granta Automation’s modular solutions can be easily adapted or expanded as your production needs evolve. This flexibility allows you to scale seamlessly without the delays, costs, and risks associated with labour fluctuations.

Total Cost of Ownership (TCO): Why Automation Pays Off

When evaluating palletising options, it’s critical to look beyond initial capital expenditure and consider the Total Cost of Ownership (TCO)—including labour, maintenance, downtime, safety-related costs, and lost productivity.

Automated palletising systems typically deliver a full return on investment within 18-24 months, driven by:

Dramatic reductions in labour and overtime costs
Increased throughput and efficiency
Lower product damage and rework expenses
Significant reductions in injury-related costs and downtime

In contrast, manual palletising operations face steadily rising costs as labour expenses increase and safety incidents accumulate.

Invest Today for a Safer, More Productive Tomorrow

While manual palletising may appear cost-effective at the outset, the cumulative costs of labour, injuries, inefficiencies, and scalability challenges add up quickly—often catching businesses off guard. Our advanced palletising solutions offer a robust business case by enhancing productivity, safety, and operational flexibility, ultimately driving long-term profitability and competitive advantage.

Investing in automation today is not just about keeping up with technology—it’s about future-proofing your operations in an increasingly complex and competitive market.

Contact us today for a quote on 01223 499488 or helpline@granta-automation.co.uk, and discover how automated palletising can revolutionise your production line.

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Is the Granta Cobot Palletiser System Future-Proof Under the New ISO 10218-2:2025 Standard?

Posted on June 18, 2025 by Granta

With the upcoming release of the ISO 10218-2:2025 robot safety standard, many manufacturers are asking whether investing in collaborative robot (cobot) systems still makes sense. A question we’ve been hearing more frequently is:

“Will the Granta cobot palletiser system become obsolete under the new robot safety regulations?”

The short answer is: No. The Granta cobot palletising system remains a compliant, future-ready solution designed with evolving safety standards in mind. Here’s why.

ISO 10218-2:2025 – What’s Changing?

The 2025 update to ISO 10218-2 is designed to consolidate robot safety requirements across traditional industrial robots and collaborative applications. Rather than separating cobots under a standalone standard (like ISO/TS 15066:2016), the new framework brings everything together.

Key changes include:

Treating “collaborative operation” as a method of use rather than a robot type.
Emphasising the importance of application-specific risk assessments.
Integrating force and speed limits from previous cobot standards into a unified document.
Encouraging flexibility in using either traditional robots or cobots—so long as the system is safe for human interaction.

This doesn’t phase out cobots—it simply means collaborative safety is no longer confined to cobot-labelled machines. Now, any robot used in a collaborative way must be safely integrated and assessed appropriately.

What Does This Mean for Your Investment in a Granta Cobot System?

At Granta Automation, we’ve designed our cobot palletiser system from the ground up to be safe, adaptable, and compliant with current and anticipated standards.

Here’s how our system meets the mark:

Built-In Safety: Our cobots feature force and power limiting, allowing them to safely operate alongside people—exactly what ISO 10218-2:2025 supports.
Future-Proof Design: The system is engineered around risk-based design principles, which continue to be the foundation of the new standard.
Flexible Operation: Whether you require full collaboration or partial segregation, our system adapts to your layout and process needs.
Ongoing Support: As the UK’s leading cobot palletiser integrator, we continuously update and support our systems to meet all relevant regulatory requirements—even as standards evolve.

Will You Need to Replace or Upgrade the System?

Absolutely not. The Granta cobot palletiser is already aligned with the key principles of the new standard. We closely follow standard updates and ensure all systems remain compliant with any future developments.

Summary

The Granta cobot palletising system is a strong, future-proof investment—fully capable of meeting the requirements of ISO 10218-2:2025 and beyond.

If you’re planning to automate palletising in your facility and want a safe, flexible system that won’t become outdated with changing regulations, our cobot solution remains one of the most forward-thinking options available.

Have further questions? Get in touch with our team today—we’d be happy to advise. 01223 499488 or helpline@granta-automation.co.uk

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Manual Palletising Wearing You Down? Here’s What You Can Do About It

Posted on June 6, 2025 by Granta

In many warehouses and production facilities across the UK and beyond, manual palletising is a daily reality—one that seems simple on the surface but leads to a surprising number of operational challenges. What often begins as a quick fix for moving finished goods onto pallets becomes a source of labour inefficiencies, quality control issues, and rising injury rates.

If you’re reading this, there’s a good chance you’re not searching for ‘automated palletisers.’ What you’re actually looking for is a better way to deal with:

Increasing palletising labour problems
Constant pallet loading issues
Growing concerns over worker fatigue and injuries
A desire to reduce palletising errors
Concerns about safety, compliance, and long-term sustainability

You’re not alone. These are the exact triggers that prompt most of our clients to reach out to Granta Automation. Not because they’re desperate for a robot—but because the traditional way of doing things just isn’t cutting it anymore.

Let’s take a closer look at why this happens, what the true costs are, and what a smarter path forward might look like.

The True Cost of Manual Palletising

It’s easy to assume that manual palletising is the cheapest option. You have the workforce already. A few training sessions and a pallet truck—job done, right?

Not quite.

Over time, businesses that rely on manual palletising begin to experience a range of persistent and costly challenges:

Worker Fatigue and Reduced Productivity
Palletising is repetitive, physically demanding work. Stacking dozens—or hundreds—of heavy items every shift leads to muscle strain, exhaustion, and slower output as the day progresses. By the end of a shift, error rates climb and motivation drops.
Staff Turnover and Labour Shortages
It’s increasingly hard to find and retain people willing to do hard manual labour, especially in competitive job markets. The result? High turnover, frequent recruitment, and training cycles that drain your time and budget.
Palletising Safety Concerns
From back injuries to slips and falls, the health and safety risks associated with manual palletising are serious. Just one incident can lead to long-term absence, HSE investigations, or even litigation.
Inconsistent Pallet Quality
Humans aren’t machines. Manual palletising leads to stacks that are often uneven or improperly aligned—especially when operators are rushing to keep up. Poorly stacked pallets increase the risk of product damage during transit or storage.
Hidden Time and Cost Drains
Even small delays add up—pauses for rest, adjusting misaligned boxes, or resolving damaged product complaints. Over a week, month, or year, these inefficiencies significantly slow down throughput and increase costs.

The Limits of “Fixing” Manual Systems

When businesses first encounter these challenges, the instinct is to tweak the existing process rather than overhaul it. Common responses include:

Rotating palletising tasks between workers
Investing in lifting aids and ergonomic supports
Redesigning the palletising area to be more efficient
Hiring additional labour during peak periods
Offering overtime to boost output

While these can provide short-term relief, they don’t solve the core problem: manual palletising is inherently limited by human capability.

Even under ideal conditions, it’s difficult to sustain quality, speed, and safety with manual stacking. And when volume spikes—or when staff call in sick—the cracks begin to show.

The Power of Automated Palletising: Solving Problems at the Source

A well-designed automated palletiser transforms the palletising process from a physical burden into a seamless, consistent, and safe operation. Here’s how:

Eliminate Manual Handling Risks
Workers no longer need to lift, twist, or stack heavy items—dramatically reducing the risk of musculoskeletal disorders and fatigue-related errors.
Ensure Consistency, Every Time
Robotic systems follow programmed patterns precisely, producing uniform, stable pallets that reduce damage during transport and improve stacking efficiency in storage.
Boost Throughput Without Additional Labour
Once configured, automated palletisers can operate continuously, at speeds far beyond what human workers can sustain—even running 24/7 with no supervision.
Reallocate Labour to Higher-Value Tasks
Staff who were previously stuck doing repetitive palletising can be trained to supervise systems, manage logistics, or focus on quality control—improving job satisfaction and productivity.
Rapid Return on Investment
Despite initial capital costs, most businesses experience ROI in 6 to 24 months, especially when factoring in savings on labour, reduced injuries, improved throughput, and fewer rejected loads.

Tailored Solutions: Not One-Size-Fits-All

At Granta Automation, we don’t believe in off-the-shelf fixes. Every business is different—different products, different stacking requirements, different floor layouts. That’s why every palletising system we deliver is fully tailored and;

Specified for your specific product dimensions, weights, and packaging types
Designed to work within your available space and production flow
Configured to suit your pallet patterns and loading sequences
Scalable to grow with your operation over time

We work with you from day one to understand your process, goals, and constraints—delivering a solution that doesn’t just work, but fits your business like a glove.

Concerned About Cost? Let’s Talk Numbers

We understand the hesitation: automation is a big step. But when we work out the numbers with our clients, the case becomes clear. Most systems we install pay for themselves within 12–18 months, thanks to:

Labour cost reductions
Decreased product damage
Lower injury and insurance claims
Increased output and consistency
Reduced downtime and staffing issues

If you’re not ready for this initial capital outlay, our palletising systems can be hired from just £2.19/hour.

We offer detailed ROI calculators and live demonstrations so you can see how it would work—before you make any decisions.

Ready to Explore What Automation Could Look Like For You?

Here’s what the first step looks like:

Step 1: Free Palletising Process Audit
We assess your current process and determine if automation is viable.
Step 2: Custom ROI Report
We give you a breakdown of cost, potential savings, and expected payback period—based on your real-world data.
Step 3: System Proposal and Timeline
If it’s a good fit, we outline exactly what your tailored system would include, along with installation timelines and training support.

There’s no obligation, and no pressure—just a clear path forward. At Granta Automation, we’re here to help you transition from reactive problem-solving to proactive improvement.

Book your free palletising audit today
Let’s solve the problems you’re already dealing with—and discover the performance you didn’t think was possible. Contact us today on 01223 499488 or helpline@granta-automation.co.uk,

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Posted in Auto Palletiser, Automated Container Unloading, Automated Palletising, Bag Palletiser, Box Palletiser, Cobot Palletiser, Compact Palletiser, Container Destuffing, Container Destuffing Palletising, Container Unloading Palletising, Depalletising, Modular Palletiser, Palletiser, Palletiser - Granta Palletiser System, Palletising, Robotic Palletiser, Robotic Palletising, Small Palletiser | Tagged palletising issues, Palletising Labour | Comments Off

Rent a Palletiser from Just £2.19/hour – Flexible, Fast and Risk-Free Automation

Posted on May 30, 2025 by Granta

Does renting a palletiser make business sense? Renting isn’t just a financial decision—it’s a strategic one. Below, we break down the key reasons why more manufacturers are turning to palletiser rental to meet production goals, improve labour efficiency, and stay ahead of the curve.

1. Avoid Capital Expenditure & Preserve Cash Flow

Purchasing automation equipment can involve significant upfront costs—often six figures or more. For many small to medium-sized manufacturers, or larger firms dealing with budget constraints, this level of investment can delay or even derail automation plans.

Renting a palletiser enables you to bring automation into your production line without tying up capital. This means you can keep your cash working in other areas of the business—whether that’s investing in staff, raw materials, product development, or marketing.

2. Predictable Operating Costs for Smarter Financial Planning

With our rental model, your palletising solution becomes a fixed, predictable operating cost. You won’t be hit with unexpected service fees, repair bills, or upgrade costs—everything is included in your rental agreement.

This predictable cost structure makes it easier to forecast budgets and measure ROI, especially when comparing the hourly rate against the cost of manual labour.

Hire rates:

£2.19/hour for 24/7 shift operation
£6.14/hour for 12-hour, 5-day-per-week shift
(Rates based on a 5-year contract)

3. Short Lead Times & Fast Deployment

In manufacturing, time lost is opportunity lost. Traditional automation solutions often come with long design, build, and installation timelines. This can leave you waiting months before your line is even up and running.

Granta Automation’s rental palletisers are available on short lead times and designed for rapid deployment. This means you can react quickly to increasing demand, short-term contracts, or capacity bottlenecks—without the usual delay or disruption.

4. Compact Footprint – Install Almost Anywhere

Space constraints are a common concern when implementing automation. The good news? Our palletising systems are designed with flexibility in mind.

In fact, they start from a footprint as small as a Smart car, meaning they can be installed in compact facilities without requiring major layout changes. Whether you’re retrofitting a legacy production line or setting up a lean manufacturing cell, our systems can be configured to fit your space.

6. Scalable for Growth & Changing Needs

What suits your production now might not meet your needs in six months. Renting offers flexibility that purchasing simply doesn’t. You can:

Start small with a single cobot palletiser
Upgrade to a larger industrial system as volumes increase
Scale up with multiple systems as new lines are added
Change configurations as product sizes, stacking patterns or pallet specs evolve

This makes palletiser rental ideal for dynamic manufacturers operating in fast-paced markets.

7. Labour Savings & Improved Health & Safety

Manual palletising is repetitive, physically demanding, and prone to injury risks. It also ties up valuable human resources in low-value tasks.

Automated palletising reduces labour dependency, improves line consistency, and creates a safer working environment. It also protects against the risk of labour shortages or absenteeism—issues many manufacturers are facing now more than ever.

In many cases, customers see:

Reduction in manual handling injuries
Increased OEE (Overall Equipment Effectiveness)
Reallocation of staff to higher-value roles

8. Expert Support

When you rent a palletiser from Granta Automation, you gain access to a team of experts who are with you every step of the way. From system design to commissioning, training, and ongoing support, we ensure your system performs reliably and continues to deliver results.

Tailored Solutions for Every Application

We offer two flexible palletising systems to meet a range of production requirements:

Cobot Palletiser (30kg payload) – Ideal for low to medium throughput operations. Safe for collaborative or industrial use and compact in design, this is a great option for manufacturers new to automation for various product types.
Industrial Robot Palletiser (140kg payload) – Built for high-speed, high-volume environments. Capable of handling heavy payloads with speed and accuracy, ideal for continuous operations and bulk palletising needs.

Each system is configured to your specific product, pallet pattern, and line speed—ensuring seamless integration and maximum efficiency.

Get Started With Automated Palletising – The Smarter Way

With rental options from just £2.19/hour, there’s never been a more accessible path to automation. Whether you’re looking to improve efficiency, reduce labour costs, boost safety, or increase throughput, renting a palletiser gives you the tools to compete and grow—without the risk.

Contact us today for a quote on 01223 499488 or helpline@granta-automation.co.uk, and discover how palletiser rental can revolutionise your production line.

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Beyond Labour Savings: The Unexpected Benefits of Robotic Palletisers

Posted on May 29, 2025 by Granta

In an era of rising costs, supply chain pressure, and persistent labour shortages, businesses are turning to automation not just as a convenience, but as a necessity. Robotic palletisers are often the first step in this journey—offering an immediate solution to repetitive manual handling tasks and a straightforward ROI in the form of labour savings.

However, the true impact of robotic palletising extends far beyond cost reduction.

At Granta Automation, we’ve delivered robotic palletising systems to organisations across many different industries and we consistently see clients uncover surprising and transformative secondary benefits they hadn’t anticipated at the point of investment.

This article explores those unexpected benefits, including both tangible and intangible gains that together form a compelling case for automation that goes far beyond spreadsheets.

1. Reduced Product Damage Through Precision Stacking

Manual palletising is prone to error—misaligned boxes, uneven weight distribution, and dropped items are all too common. Over time, these mistakes can result in significant product damage, particularly in high-throughput or fragile goods operations.

Robotic palletisers offer a precision that human labour simply can’t match. With advanced programming, intelligent motion control, and accurate placement tools, these systems ensure that every product is stacked in the most stable and compact configuration possible. This reduces:

Transit damage
Packaging degradation
Customer complaints
Waste and rework

The result is a higher-quality product presentation, greater customer satisfaction, and stronger brand reputation—all of which feed back into business growth.

2. Improved Workplace Safety and Lower Staff Turnover

Palletising is a high-risk, high-fatigue task. It demands repetitive bending, lifting, and twisting, which are leading causes of workplace injury. These injuries cost businesses through time off, compensation claims, and rising insurance premiums.

By automating these tasks, businesses dramatically improve workplace safety. Employees are freed from repetitive strain and can be redeployed to less hazardous, more fulfilling roles. This leads to:

Fewer injuries and near-misses
Reduced absenteeism
Better staff morale
Lower recruitment and training costs

In an industry where employee retention is often a challenge, this shift makes a substantial difference.

3. Maximised Space Utilisation with Smarter Pallet Configurations

One of the underappreciated advantages of robotic palletisers is their ability to optimise every square metre of storage space. Manually stacked pallets often vary in height and stability, leading to inefficient use of racking and transportation space.

Robotic systems, by contrast, create uniform, dense, and stable pallets every time. This has direct implications for:

Warehouse storage capacity
Racking system efficiency
Container and lorry fill rates
Floor space for operational activities

By improving stack quality, robotic palletisers help you do more with less—freeing up space, reducing warehouse costs, and supporting a more scalable operation.

4. Built-In Scalability for Future Growth

Growth brings challenges. As demand increases, relying on manual labour to scale up production becomes a limiting factor. Labour markets are tight, training takes time, and inconsistency creeps in as volumes increase.

Robotic palletisers are inherently scalable. Modular in design, they can be adapted to handle:

Higher throughput
New product types or sizes
Multi-line palletising
Integration with other automation systems

This means businesses can respond to new opportunities without being constrained by workforce limitations—a competitive advantage in fast-moving markets.

5. Enhanced Consistency and Quality Control

Whether you’re dealing with pharmaceuticals, food, or high-value industrial goods, consistency is non-negotiable. Robotic palletisers ensure the same quality and accuracy on the 10,000th pallet as on the first.

They can also be integrated with vision systems, barcode scanners, and quality assurance software to monitor:

Correct product orientation
Barcode accuracy
Packaging damage detection
Label presence and positioning

This allows for real-time quality control at the point of packaging—eliminating errors before they become customer problems.

6. Operational and Energy Efficiency

While labour savings often drive investment, energy savings can significantly add to long-term ROI. Robotic palletisers are energy efficient, running only when required, and consuming less power per cycle compared to legacy machinery or inconsistent manual operations.

They also contribute to leaner, more efficient workflows by integrating seamlessly with conveyors, sensors, and smart scheduling systems.

7. Access to Real-Time Data and Performance Monitoring

Modern robotic systems generate vast amounts of actionable data. This includes:

Number of pallets completed
Cycle times and efficiency
Error logs and downtime alerts
Predictive maintenance prompts

This data enables better decision-making and proactive maintenance, ensuring the palletising line continues to run efficiently without costly interruptions.

8. The Often Overlooked: Intangible Benefits That Drive Real Value

While measurable benefits are critical for justifying capital expenditure, intangible benefits often deliver the most lasting impact. These are the improvements that change how your team works, how your customers perceive you, and how confidently you can plan for the future.

Based on our extensive work with clients, here are some key intangible benefits that robotic palletising provides:

Reduced Workplace Stress
When staff are no longer burdened with physically demanding, repetitive tasks, stress levels drop. Supervisors no longer have to deal with daily staffing issues, fatigue-related errors, or health and safety concerns. The entire environment becomes calmer, more focused, and more resilient.
Improved Customer Perception
Consistent, well-packaged pallets improve how customers view your professionalism and product care. Deliveries arrive intact and correctly labelled—helping to build trust and secure repeat business.
Greater Confidence in Meeting Deadlines
With robotic palletisers in place, there’s less risk of production delays due to absenteeism or manual bottlenecks. This gives your operations team more confidence in hitting dispatch targets, and gives your sales team confidence to promise delivery timelines.
Enhanced Team Morale
By automating mundane tasks, staff are reassigned to more meaningful roles—often involving equipment oversight or process improvement. This investment in people as well as technology leads to higher morale and stronger team engagement.
Reduced Management Burden
Fewer operational fires to fight means more time spent on strategic planning, process improvement, and growth initiatives. Managers benefit from smoother operations and more predictable performance.

Final Thoughts: Robotic Palletisers as Strategic Enablers

While labour savings may be the trigger for considering robotic palletising, they are rarely the most valuable outcome. Companies that embrace automation quickly realise they’ve invested in:

At Granta Automation, we design and deliver custom palletising systems that address the full scope of your operation—not just your labour line item. Our solutions are built for performance, flexibility, and long-term return on investment, incorporating the tangible and intangible benefits that drive modern manufacturing excellence.

👉 Learn how automation can transform your operations—ask for a link to our customer testimonials!

From high-volume manufacturers to niche producers, our systems are making a measurable impact—see what’s possible when you go beyond labour savings.

If you would like to know more about the Granta palletising systems or AMR/AGV systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk. We will be very happy to help.

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Posted in Auto Palletiser, Automated Container Unloading, Automated Palletising, Bag Palletiser, Box Palletiser, Cobot Palletiser, Compact Palletiser, Container Destuffing, Container Destuffing Palletising, Container Unloading Palletising, Depalletising, Modular Palletiser, Palletiser, Palletiser - Granta Palletiser System, Palletising, Robotic Palletiser, Robotic Palletising, Small Palletiser | Tagged automated palletiser benefits, palletiser benefits | Comments Off

How to Convince Decision-Makers to Invest in Automation

Posted on May 21, 2025 by Granta

A Practical Guide to Securing Buy-In and Driving Operational Change

Automation is no longer a future concept—it’s an operational imperative. Businesses that embrace automation are not only improving efficiency but also gaining a competitive edge in terms of cost control, delivery speed, and workforce agility.

Yet, despite the clear advantages, one of the most common barriers to automation isn’t technology or capability—it’s internal alignment. Getting leadership buy-in is often the most difficult hurdle in moving an automation project from idea to implementation.

Whether you’re an operations manager, engineering lead, or continuous improvement specialist, here’s a step-by-step guide to building a robust, board-ready business case for automation—one that resonates with decision-makers and secures the support your project needs to move forward.

1. Speak the Language of ROI, Payback, and Strategic Value

When you’re presenting automation to senior leadership, the conversation needs to go beyond technical functionality. What decision-makers care most about is return on investment, cost justification, and business impact.

Key metrics to focus on:

Payback period – Show how quickly the system will pay for itself. Many palletising systems, especially those on rental agreements, achieve ROI in 12–18 months or less.
Total cost of ownership – Outline all costs and savings over a 2–5 year period, including labour reduction, improved productivity, fewer errors, and reduced HSE claims.
Hourly cost comparison – For example, renting a palletiser from just £2.19/hour is often significantly lower than manual labour costs.
Long-term savings – Highlight cumulative labour savings over time and the reduction in recruitment, training, and absenteeism-related costs.

Tie the numbers directly to strategic objectives: improving throughput, enhancing quality, reducing overheads, and future-proofing the business.

2. Anticipate and Overcome Common Objections

Leadership teams will likely raise a number of concerns. Anticipate these objections and prepare confident, data-backed responses.

Objection: “It’s too expensive.”

Explain that automation is not a sunk cost—it’s a value-generating asset. Renting also allows you to implement automation with minimal capital outlay and immediate operational benefits. For example, a palletiser can often replace multiple manual roles for a fraction of the cost.

Objection: “We don’t have the skills to run it.”

Modern automation solutions are designed with user-friendly interfaces and minimal maintenance requirements. Granta Automation palletising systems come with full training and support, and are intuitive enough for line operatives to manage with ease.

Objection: “What about our existing workforce?”

Reframe automation as a tool to augment, not replace. By eliminating repetitive, injury-prone tasks like manual palletising, staff can be redeployed into safer, more skilled, and value-adding roles. This improves morale, reduces turnover, and supports employee retention.

3. Use Case Studies and Real-World Success Stories

Abstract concepts are hard to justify in the boardroom—but real-world results are persuasive. Bring your case to life with data and stories from similar companies that have implemented palletising automation.

Include:

Before-and-after stats – e.g. a 40% reduction in palletising labour, 20% uplift in throughput, 100% reduction in manual handling injuries.
Video testimonials from industry peers – Hearing directly from companies who have successfully implemented automation is one of the most compelling forms of evidence. Real-world feedback from operations managers and business leaders—captured on video—adds authenticity and credibility, showing decision-makers exactly how automation has delivered measurable results in similar environments.
Images or video – A short clip of the system in action can often do more than a 10-page report.

If you’re working with Granta Automation, we can provide case studies to demonstrate proven success—clearly showing that automation has been implemented effectively by businesses like yours, with measurable and repeatable results.

4. Position Automation as a Strategic Enabler, Not Just a Cost Saver

Automation is often viewed narrowly as a way to cut labour costs. But forward-thinking companies know that it’s also a powerful enabler of agility, scalability, and resilience.

Frame automation as a way to:

De-risk operations by reducing dependence on variable labour supply
Scale output quickly to meet changing demand, without increasing headcount
Ensure consistency in stacking, packaging, and dispatch, which improves quality control
Improve customer satisfaction through faster lead times and fewer errors
Stay competitive in an industry where automation adoption is accelerating

Automation is no longer a nice-to-have—it’s a competitive necessity.

5. Tailor the Pitch to Your Audience

Board members have different priorities, and a one-size-fits-all pitch won’t resonate equally with everyone. Tailor your message:

Finance Directors will want to see hard numbers: ROI, leasing vs. capex options, cost avoidance, and profit impact.
Operations Managers will focus on throughput, system reliability, downtime reduction, and line efficiency.
HR and HSE teams will be interested in staff impact, safety improvements, training requirements, and workforce retention.

Show how automation benefits the whole organisation—not just the production line.

Ready to Present to the Board?

If you’re preparing to pitch a palletising automation solution to senior leadership, we’re here to help you make the strongest case possible.

Our Board Room Pack includes:

Detailed ROI analysis tailored to your business
Testimonials from companies that have installed a Granta palletiser system
System specifications, layout drawings, and cycle time data
Talking points to address key stakeholder concerns

Need to present your palletiser quote to the board? Ask us for a board room pack!
We’ll help you walk into that meeting fully prepared—and walk out with project approval.

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Posted in AGVs, AMRs, Auto Palletiser, Automated Container Unloading, Automated Palletising, Bag Palletiser, Box Palletiser, Cobot Palletiser, Compact Palletiser, Company news, Container Destuffing, Container Destuffing Palletising, Container Unloading Palletising, Depalletising, Modular Palletiser, Palletiser, Palletiser - Granta Palletiser System, Palletising, Robotic Palletiser, Robotic Palletising, Small Palletiser | Tagged case automation, present automation | Comments Off

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