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.

contact us

Bag PalletiserBag Palletiser
Barrel PalletiserBarrel Palletiser
Box PalletiserBox Palletiser
Crate PalletiserCrate Palletiser
Tray PalletiserTray Palletiser
Posted in Cobot Palletiser, Company news, Granta Updates, Palletiser, Palletiser - Granta Palletiser System, Palletising, Robotic Palletiser, Robotic Palletising, Small Palletiser | Tagged , | Comments Off on How Fast Can My Cobot Run Without Guarding?

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.

contact us

Bag PalletiserBag Palletiser
Barrel PalletiserBarrel Palletiser
Box PalletiserBox Palletiser
Crate PalletiserCrate Palletiser
Tray PalletiserTray Palletiser
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, Granta Updates, Modular Palletiser, Palletiser, Palletiser - Granta Palletiser System, Palletising, Robotic Palletiser, Robotic Palletising, Small Palletiser | Tagged , | Comments Off on Manual Palletising vs Automated Palletising: Understanding the True Cost

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

 

contact us

Bag PalletiserBag Palletiser
Barrel PalletiserBarrel Palletiser
Box PalletiserBox Palletiser
Crate PalletiserCrate Palletiser
Tray PalletiserTray Palletiser
Posted in Cobot Palletiser, Company news, Granta Updates, Palletiser, Palletising, Robotic Palletiser, Robotic Palletising, Small Palletiser | Tagged | Comments Off on Is the Granta Cobot Palletiser System Future-Proof Under the New ISO 10218-2:2025 Standard?

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:

  1. 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.
  2. 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.
  3. 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.
  4. 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.
  5. 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,

contact us

Bag PalletiserBag Palletiser
Barrel PalletiserBarrel Palletiser
Box PalletiserBox Palletiser
Crate PalletiserCrate Palletiser
Tray PalletiserTray Palletiser
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 , | Comments Off on Manual Palletising Wearing You Down? Here’s What You Can Do About It

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.

contact us

Bag PalletiserBag Palletiser
Barrel PalletiserBarrel Palletiser
Box PalletiserBox Palletiser
Crate PalletiserCrate Palletiser
Tray PalletiserTray Palletiser
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 , | Comments Off on Rent a Palletiser from Just £2.19/hour – Flexible, Fast and Risk-Free Automation

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:

  • Improved quality
  • Increased safety
  • Higher throughput
  • Greater consistency
  • Scalable growth capacity
  • Improved workplace culture
  • Elevated customer experiences

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.

contact us

Bag PalletiserBag Palletiser
Barrel PalletiserBarrel Palletiser
Box PalletiserBox Palletiser
Crate PalletiserCrate Palletiser
Tray PalletiserTray Palletiser
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 , | Comments Off on Beyond Labour Savings: The Unexpected Benefits of Robotic Palletisers

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.

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.

contact us

Bag PalletiserBag Palletiser
Barrel PalletiserBarrel Palletiser
Box PalletiserBox Palletiser
Crate PalletiserCrate Palletiser
Tray PalletiserTray Palletiser
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 , | Comments Off on How to Convince Decision-Makers to Invest in Automation

Stack Smarter, Not Harder: The Business Case for Robotic Palletisers

Posted on May 13, 2025 by Granta

In today’s fast-paced manufacturing and distribution environments, efficiency isn’t just about speed—it’s about consistency, safety, and reliability. And nowhere is this more evident than in the palletising process. At first glance, stacking pallets might seem like a simple, low-impact task. But in reality, it plays a crucial role in safeguarding product quality, protecting your bottom line, and keeping your operations running smoothly.

This is where robotic palletisers come into their own. With the ongoing labour challenges across the industry, the increasing cost of product damage during transit, and the ever-growing pressure to improve health and safety, more companies are choosing to automate their palletising process. In this article, we’ll explore why robotic palletisers are becoming a must-have investment for manufacturers of all sizes—and how they can transform the way you stack.

Manual Palletising: Small Errors, Big Costs

Manual pallet stacking is a labour-intensive process that relies heavily on individual attention to detail, physical stamina, and on-the-spot decision-making. Unfortunately, even the most experienced operatives can make mistakes—particularly when under time pressure or dealing with repetitive tasks over long shifts.

The most common issues caused by manual stacking include:

  • Inconsistent stack height and alignment, leading to unstable pallets.
  • Overhanging product, which not only risks damage but also wastes valuable pallet and lorry space.
  • Human error, such as missed boxes, improper stacking sequences, or improper wrapping.

These issues might seem minor on an isolated basis, but when scaled up across hundreds or thousands of pallets a week, the cost can be significant. Not only can it result in product returns and wasted materials, but it can also create delays in shipping, increase customer complaints, and lead to potential health and safety breaches on the shop floor.

Robotic Palletisers: Built for Precision and Performance

Unlike manual operators, robotic palletisers don’t suffer from fatigue, distraction, or inconsistency. They follow programmed patterns with millimetre precision—every pallet, every time. This repeatability is where the true value of automation lies.

With a robotic palletising system, you benefit from:

  • Perfectly aligned, stable stacks, reducing the risk of tipping or collapse.
  • Optimised pallet configurations, using space more efficiently and fitting more product per load.
  • High-speed performance, significantly increasing throughput without compromising quality.

Advanced systems also allow for flexible pallet patterns, meaning the robot can handle different products, packaging types, and stack formats with ease. Whether you’re stacking heavy cartons, shrink-wrapped trays, or awkwardly shaped boxes, a robotic palletiser can be programmed to adapt.

The Link Between Stack Quality and Product Returns

Many manufacturers don’t realise how closely product returns are linked to palletising quality. Damaged goods often occur after they’ve left your facility—due to shifting during transit, poor support, or crushed packaging from unstable stacking. Every return represents lost time, additional handling costs, and potential loss of future business.

Robotic palletisers dramatically reduce these issues by ensuring every pallet is stacked to the exact same high standard. Products arrive in perfect condition, customers receive what they expect, and your reputation for quality remains intact.

In some industries, this consistency can also help meet customer compliance standards or transport regulations. For example, food, pharmaceutical, or retail sectors often require uniform pallet loads for automated warehousing systems or store deliveries. Robotic palletising helps ensure these requirements are met—every time.

A Smarter Investment for Long-Term Gains

While the upfront cost of a robotic palletiser can be a concern for some businesses, the long-term financial benefits are compelling. Over time, most companies find the investment pays for itself through a combination of labour savings, reduced waste, lower return rates, and increased productivity.

Here’s how the savings stack up:

  • Reduced Labour Costs: A single robotic palletiser can do the work of multiple manual operators, freeing staff for higher-value tasks elsewhere in the facility.
  • Lower Product Damage: Consistent, stable stacking greatly reduces product losses in the warehouse and in transit.
  • Improved Throughput: Robotic systems maintain high speeds and continuous output, helping meet rising customer demand without increasing headcount.
  • Health & Safety Improvements: Automation reduces repetitive strain injuries and lowers the risk of accidents related to heavy lifting and poor stacking.
  • Scalability and Flexibility: As your production grows or product lines change, robotic palletisers can be easily reprogrammed to handle new tasks.

In many cases, grants or capital allowances can also help offset the initial investment—particularly where automation improves efficiency and reduces waste. Or palletisers can be hired or purchased on a leasing scheme to remove the need for capital outlay.

Is Now the Right Time to Automate?

If your business is experiencing growing volumes, labour shortages, or high return rates due to product damage, then now could be the perfect time to consider automation. Robotic palletisers aren’t just a solution for large-scale manufacturers—they can be tailored to suit operations of all sizes and complexities.

Whether you’re looking to improve stack quality, free up staff time, or future-proof your production line, robotic palletising offers a clear return on investment.

Find Out More

At Granta Automation, we specialise in designing and installing fully automated palletising systems that are tailored to your specific needs. Our systems integrate seamlessly with your existing processes, and our expert team can help you identify the most cost-effective way to implement automation on your line.

To learn more or to arrange a free on site assessment, get in touch with us today on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

contact us

Bag PalletiserBag Palletiser
Barrel PalletiserBarrel Palletiser
Box PalletiserBox Palletiser
Crate PalletiserCrate Palletiser
Tray PalletiserTray Palletiser
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, Granta Updates, Modular Palletiser, Palletiser, Palletiser - Granta Palletiser System, Palletising, Robotic Palletiser, Robotic Palletising, Small Palletiser | Tagged , | Comments Off on Stack Smarter, Not Harder: The Business Case for Robotic Palletisers

Granta’s Portable Cobot Palletising System: High-Performance Automation That Moves With You

Posted on April 23, 2025 by Granta

In today’s rapidly evolving manufacturing landscape, the pressure to increase efficiency, reduce downtime, and remain adaptable to shifting production demands has never been greater. Traditional automation systems, while effective, often lack the flexibility to keep up. That’s where Granta Automation’s portable cobot palletising system comes in—offering a bold new approach to palletising that combines industrial-grade performance with collaborative safety and unmatched mobility.

This isn’t just a robot—it’s a smart, portable palletising solution designed to scale with your business, flex with your workflow, and work seamlessly alongside your people.

Built for the Future of Manufacturing

At the heart of the Granta portable cobot palletising system is an advanced 30kg payload collaborative robot (cobot) that can be configured for a wide range of palletising tasks. From high-throughput environments to smaller production runs, this cobot is engineered to deliver speed, reliability, and adaptability—all while maintaining the safety standards required in today’s operations.

Key capabilities include:

  • High payload collaborative performance
    The 30kg payload capacity makes it suitable for handling items with ease, including cases, bags, boxes, and other goods.
  • Engineered for 24/7 use
    Built with industrial-grade components, the system is capable of running around the clock in tough environments.
  • Plug-and-play deployment
    Fast installation and easy integration into existing production lines make it an ideal solution for facilities looking to minimise downtime and accelerate automation.
  • Variety of gripper options
    A variety of grippers can be used, enabling the system to handle different packaging types and product sizes, offering flexibility across SKUs and applications.
  • Flexible safety configurations
    Whether running in fully collaborative mode or in high-speed industrial mode with additional safety, the system adapts to your workspace and safety requirements.
  • Portable design
    The entire system is built to be moved quickly and easily between production lines—transforming how automation is deployed on the shop floor.

Dual-Mode Functionality: Speed Meets Safety

One of the standout features of the Granta system is its ability to operate in both collaborative and industrial robot modes—switching between the two based on the safety systems in place.

In collaborative mode, the cobot operates at a reduced speed and uses built-in force sensing to detect any unexpected contact. If interference is detected, the system immediately stops and waits for confirmation that it is safe to resume operation.

In industrial robot mode, when the cobot is operating within a fully secured area with guarding, light curtains, or safety scanners, it can run at full speed. This mode significantly boosts throughput while still maintaining safe operation in accordance with industry standards.

This dual capability ensures that manufacturers don’t need to compromise on either safety or performance. The system intelligently adapts to its environment, delivering high output when conditions allow, and maximum safety when needed.

The Game-Changer: Portability

The true differentiator of the Granta cobot palletising system is its portability. Traditional palletisers are fixed in place, often tied to a single production line or process. The Granta portable cobot system breaks that mould with a mobile design that can be relocated quickly and efficiently.

Benefits of portability include:

  • Maximised equipment utilisation
    Instead of investing in separate palletising systems for each production line—which may sit idle for long periods—a single Granta cobot palletiser can be shared across multiple lines. This means better use of capital and higher return on investment.
  • Operational flexibility
    Production priorities shift, new product lines are introduced, or unexpected bottlenecks occur. A portable palletiser allows you to respond to these changes immediately, without waiting for new infrastructure to be installed.
  • Reduced capital investment
    By sharing a single palletising system across multiple areas, businesses can lower their initial investment while still gaining the full benefits of automation.
  • Faster changeovers
    The system is designed for rapid redeployment. It can be moved, reconfigured, and reprogrammed with minimal effort, enabling agile manufacturing strategies and shorter setup times.

This approach to automation is perfectly aligned with modern manufacturing practices that favour flexibility, scalability, and responsiveness over rigid, fixed infrastructure.

Safety Configurations to Suit Every Operation

To meet different workplace requirements, the Granta cobot palletiser is available in three main safety configurations:

  • Collaborative-only (no guarding)
    This configuration runs exclusively in collaborative mode at reduced speeds. It is suitable for environments where human-robot interaction is frequent and space is limited.
  • Guarding with scanner
    In this setup, the cobot operates at full industrial speed while the area is secure. If the scanner safety detects someone move into the safety zone the cobot switches to collaborative mode. Once the area is cleared and confirmed safe, full-speed operation resumes.
  • Safety area scanners
    With safety scanners in place, the cobot monitors its surroundings in real-time. If a person enters the designated safety zone, the cobot automatically slows to collaborative speed. When the area is clear again, it resumes full-speed operation. This setup offers a dynamic and efficient balance between productivity and safety.

Each configuration is designed to help businesses choose the right balance between throughput, safety, and layout requirements.

Ready for Smart Factory Integration

The Granta system is not just about palletising—it’s designed to be part of a broader smart factory ecosystem. It can be seamlessly integrated with:

  • AMRs (Autonomous Mobile Robots)
    Allowing pallets to be transported autonomously throughout the facility, streamlining material flow and reducing reliance on manual handling.
  • AGVs (Automated Guided Vehicles)
    Enabling a fully automated end-of-line system that handles both palletising and pallet transport with minimal human involvement.

By connecting the cobot to other automated systems, manufacturers can take another step toward building a fully digital, scalable, and efficient production environment.

Why Choose Granta?

Granta’s portable cobot palletising system is a strategic investment for any business looking to stay ahead in today’s competitive industrial landscape. It brings together the performance of industrial robotics, the safety of collaborative automation, and the adaptability of a portable, modular palletising solution.

When you choose Granta, you’re choosing:

  • A high-performance 30kg payload cobot
  • Built-for-purpose durability and 24/7 readiness
  • Intuitive easy programming software and quick-changeover capability
  • Flexible safety options to match your environment
  • True portability that unlocks multi-line flexibility
  • Seamless integration with AMRs and AGVs

This is automation on your terms—fast, smart, and designed to move with your business.

Get a Quote Today

If you’re ready to take your palletising automation to the next level, we’re ready to help. To receive your rapid cobot palletiser budget quote, simply click here and fill in your requirements. A member of our team will be in touch to discuss the best solution for your facility.

Move faster. Work smarter. Automate better.

If you would like to know more, feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk.

 

contact us

Bag Palletiser

Bag Palletiser

Barrel Palletiser

Barrel Palletiser

Box Palletiser

Box Palletiser

Crate Palletiser

Crate Palletiser

Tray Palletiser

Tray Palletiser

Posted in Auto Palletiser, Automated Palletising, Box Palletiser, Cobot Palletiser, Compact Palletiser, Modular Palletiser, Palletiser, Palletiser - Granta Palletiser System, Palletising, Robotic Palletiser, Robotic Palletising, Small Palletiser | Tagged , | Comments Off on Granta’s Portable Cobot Palletising System: High-Performance Automation That Moves With You

Manual vs. Automatic Palletising: A Comprehensive Comparison

Posted on April 9, 2025 by Granta

Palletising plays a crucial role in manufacturing, warehousing, and logistics by ensuring products are efficiently stacked for transportation and storage. As businesses strive for greater efficiency and cost-effectiveness, they must choose between manual and automatic palletisers.

While manual palletising relies on human labour, automatic palletisers use advanced machinery and robotics to streamline operations. Each method has its advantages and disadvantages, and choosing the right one depends on factors such as production volumes, cost, efficiency, and business size and growth expectations.

In this comprehensive palletiser comparison, we will explore the differences between manual and automatic palletisers, examining their cost implications, efficiency levels, and long-term impact on operations.

What Are Palletisers, and Why Are They Important?

Palletisers are used to systematically stack, organise, and secure products onto pallets, making them easier to transport, store, and distribute. They are essential in industries such as:

  • Food and Beverage
  • Pharmaceuticals
  • Consumer Goods
  • Retail and E-commerce
  • Manufacturing

Efficient palletising ensures that products remain stable and intact, reducing damage during shipping and enhancing supply chain productivity. The choice between manual vs. automatic palletisers depends on a company’s scale of operations, budget, labour availability, and long-term growth plans.

Manual Palletising: How It Works & Key Advantages

Manual palletising involves workers physically stacking products onto pallets. Some businesses may incorporate basic tools and equipment, such as:

  • Roller conveyors to move products closer to workers
  • Lift-assist devices to reduce strain on employees
  • Forklifts and pallet jacks to transport completed pallets

While manual palletising provides flexibility, it relies on human labour, which can become physically demanding and less efficient as production volumes increase.

Advantages of Manual Palletising

  • Low Initial Investment – Manual palletising requires little to no upfront capital investment compared to automated systems.
  • Flexibility for Varied Products – Human workers can quickly adjust to different product types, sizes, and shapes without needing reprogramming or specialised setups.
  • Minimal Maintenance Costs – Unlike automated systems that can require regular software updates and mechanical servicing, manual palletising has low maintenance expenses.
  • Ideal for Small and Medium-Sized Businesses (SMBs) – Companies with very low production volumes benefit from the cost-effectiveness and adaptability of manual palletising.

Challenges of Manual Palletising

  • Labour-Intensive and Slower Productivity – Human workers cannot match the speed and efficiency of automated palletisers, leading to potential bottlenecks in high-demand operations.
  • Higher Long-Term Costs – While initial costs are lower, ongoing labour expenses (wages and associated costs, training, worker benefits etc.) can add up over time.
  • Increased Risk of Workplace Injuries – Manual lifting, repetitive movements, and improper ergonomics contribute to workplace injuries, such as back strain and musculoskeletal disorders.
  • Inconsistent Stacking & Higher Error Rates – Variations in human performance can lead to unstable pallet loads, increasing the risk of product damage during transit.

Best Use Cases for Manual Palletising

Manual palletising is ideal for businesses with:

  • Low production volumes
  • Frequent changes in product type or packaging, or irregular shaped packaging
  • Limited space for automation equipment
  • Tight budgets that cannot accommodate large capital investments

Automatic Palletising: How It Works & Key Advantages

Automated palletisers use mechanised or robotic systems to efficiently stack items onto pallets with minimal human intervention. These systems can be fully automated or semi-automated, depending on the level of human involvement required.

Types of automatic palletisers include:

  • Robotic Palletisers – These use robotic arms to pick and place items in pre-programmed stacking patterns.
  • Layer Former Palletisers – Typically operate from an elevated platform and move products into position before arranging whole layers on pallets.
  • Cobot Palletisers – Use robotic arms to pick, position, and stack products onto pallets, operating safely alongside human workers.

Advantages of Automatic Palletising

  • Superior Speed & Productivity – Automated systems work at high speeds, handling thousands of products per hour, significantly increasing throughput.
  • Consistency & Precision – Unlike human labour, automated palletisers eliminate stacking errors and ensure uniform pallet loads, reducing the risk of product damage.
  • Lower Long-Term Costs – Although the initial investment is high, businesses save money in the long run by reducing labour expenses and increasing efficiency.
  • Enhanced Workplace Safety – Automation minimises manual lifting and repetitive strain, leading to fewer workplace injuries and associated costs.
  • Seamless Integration with Production Lines – Automated palletisers can connect with conveyor systems, packaging lines, and warehouse management software, optimising supply chain operations.

Challenges of Automatic Palletising

  • High Upfront Costs – Purchasing, installing, and maintaining automated palletisers requires a significant capital investment unless you use a company like Granta that offers hire or leasing options on their palletisers.
  • Limited Flexibility for Frequent Product Changes – Initially, setup may require specific programming for each product type, unless you install an easy program palletising system like the Granta patented easy programming software that can be programmed in minutes by your staff.
  • Requires Trained Operators & Maintenance – Employees must be trained to operate, troubleshoot, and maintain automated palletisers.

Best Use Cases for Automatic Palletising

Automatic palletisers are ideal for businesses with:

  • High production volumes requiring fast throughput
  • Consistent packaging sizes and pallet configurations, although system with easy programming software can easily accommodate frequent product changes.
  • A focus on cost reduction through automation
  • The need for enhanced workplace safety and efficiency

Manual vs. Automatic Palletisers: A Side-by-Side Comparison

Manual PalletisingAutomatic Palletising
Initial InvestmentLowHigh
Long-Term CostsHigh (due to labour)Lower (savings on labour)
Productivity SpeedSlowerFaster
Stacking AccuracyVariable (human error)High (consistent and precise)
Workplace SafetyRisk of injuriesSafer (less manual handling)
Adaptability to Different ProductsHigh (workers can adjust quickly)Lower if the system does not have easy programming software (requires reprogramming)
Production ContinuityIntermittent production due to staff stopping for breaks, holidays, sickness and unexpected absences.Continuous production due to no stopping for breaks, holidays, sickness, unexpected absences.
Best forSmall businesses, with low production volumesHigher-volume production, scalability, reliability

Which Palletising System Is Right for Your Business?

For companies with very low production volumes where palletising is not required for more than 3-4 hours per day, manual palletising may remain the most cost-effective and adaptable solution. These businesses benefit from the lower initial investment and the ability to handle diverse packaging requirements.  However, companies experiencing growth and increased demand may consider semi-automated palletising as a transition towards full automation.

Companies that require high efficiency, fast throughput, and consistent quality benefit from automatic palletising systems. The long-term cost savings, increased speed, and enhanced safety make automation the preferred choice for large-scale manufacturers.

In today’s evolving business landscape, the way customers view companies using robots and automation can influence brand perception. Adopting automation can help improve efficiency and demonstrate that your business is keeping up with new technologies—something many customers appreciate. Including this in your marketing strategy can show that you’re thinking ahead and looking for smarter ways to operate. On the other hand, avoiding automation may risk making your business seem a step behind, especially as more companies move in that direction.

Choosing between manual vs. automatic palletisers depends on your business’s budget, production scale, and long-term goals.

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.

contact us

Bag PalletiserBag Palletiser
Barrel PalletiserBarrel Palletiser
Box PalletiserBox Palletiser
Crate PalletiserCrate Palletiser
Tray PalletiserTray Palletiser
Posted in Auto Palletiser, 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 , | Comments Off on Manual vs. Automatic Palletising: A Comprehensive Comparison