{"id":2835,"date":"2025-08-15T14:21:30","date_gmt":"2025-08-15T14:21:30","guid":{"rendered":"https:\/\/www.granta-automation.co.uk\/news\/?p=2835"},"modified":"2025-08-15T14:31:05","modified_gmt":"2025-08-15T14:31:05","slug":"how-many-boxes-per-hour-can-a-robotic-palletiser-handle","status":"publish","type":"post","link":"https:\/\/www.granta-automation.co.uk\/news\/how-many-boxes-per-hour-can-a-robotic-palletiser-handle\/","title":{"rendered":"How Many Boxes Per Hour Can a Robotic Palletiser Handle?"},"content":{"rendered":"\n

Breaking Down the Maths Behind Pick Rates, Patterns, and Productivity<\/strong><\/p>\n\n\n\n

When considering the investment in a robotic palletising system, one of the first questions manufacturers ask is: \u201cHow many boxes per hour can it actually handle?\u201d<\/em><\/p>\n\n\n\n

The answer isn\u2019t a vague estimate\u2014it\u2019s a straightforward calculation based on pick rates and how products are grouped during each pick. While exact performance depends on the product, pallet pattern, and gripper configuration, a few simple examples can give you a clear picture of what\u2019s realistically achievable.<\/p>\n\n\n\n

Let\u2019s walk through the maths.<\/p>\n\n\n\n

A Conservative Baseline: 330 Picks Per Hour<\/strong><\/p>\n\n\n\n

Although many robotic palletisers are capable of higher speeds, we\u2019ll use 330 picks per hour as a conservative benchmark. This is slower than the typical rate, but provides a solid baseline for planning.<\/p>\n\n\n\n

At this pick rate, you only need an average of 2.4 boxes per pick to reach over 790 boxes per hour.  Here\u2019s how different stacking patterns affect that outcome:<\/p>\n\n\n\n

<\/p>\n\n\n\n

Example 1: 10 Boxes Per Layer<\/strong><\/p>\n\n\n\n

\"\"<\/a><\/figure>\n\n\n\n

Picked in 3 rows (approx. 3\u20134 boxes per row)<\/p>\n\n\n\n

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Calculation<\/strong>:
10 boxes \u00f7 3 picks = 3.33 boxes per pick on average
At 330 cycles per hours = 3.33 boxes x 250 picks\/hour = 1099 boxes per hour<\/strong><\/p>\n\n\n\n

This is a common, efficient pattern where grouped picks deliver strong output while maintaining stack stability.<\/p>\n\n\n\n

<\/p>\n\n\n\n

Example 2: 5 Boxes Per Layer<\/strong><\/p>\n\n\n\n

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Picked in 2 rows (e.g. 3 + 2 boxes)<\/p>\n\n\n\n

\"\"<\/a><\/figure>\n\n\n\n

Calculation<\/strong>:
5 boxes \u00f7 2 picks = 2.5 boxes per pick on average
At 330 cycles per hour = 2.5 boxes x 330 picks\/hour = 825 boxes per hour<\/strong><\/p>\n\n\n\n

Even with smaller layers, efficient pick grouping can deliver well over 800 boxes per hour.<\/p>\n\n\n\n

<\/p>\n\n\n\n

Example 3: 7 Boxes Per Layer<\/strong><\/p>\n\n\n\n

Two options here depending on your tolerance for gaps in the stack:<\/p>\n\n\n\n

Option A: Preserve Gaps<\/strong><\/p>\n\n\n\n

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Picked in 5 rows<\/p>\n\n\n\n

\"\"<\/a><\/figure>\n\n\n\n

Calculation<\/strong>:
7 boxes \u00f7 5 picks = 1.4 boxes per pick on average
At 330 cycles per hour = 1.4 boxes x 330 picks\/hour = 462 boxes per hour<\/strong><\/p>\n\n\n\n

<\/p>\n\n\n\n

Option B: Remove The Gaps<\/strong><\/p>\n\n\n\n

Picked in 3 rows<\/p>\n\n\n\n

\"\"<\/a><\/figure>\n\n\n\n

Calculation<\/strong>:
7 boxes \u00f7 3 picks = 2.33 boxes per pick on averageAt 330 cycles per hour = 2.33 boxes x 330 picks\/hour = 768<\/strong> boxes per hour<\/strong><\/p>\n\n\n\n

This example shows how adjusting the pattern can significantly affect throughput\u2014even when the number of boxes stays the same.<\/p>\n\n\n\n

<\/p>\n\n\n\n

Example 4: 20 Boxes Per Layer<\/strong><\/p>\n\n\n\n

\"\"<\/a><\/figure>\n\n\n\n

Picked in 4 rows (5 boxes per row)<\/p>\n\n\n\n

\"\"<\/a><\/figure>\n\n\n\n

Calculation<\/strong>:<\/p>\n\n\n\n

20 boxes \u00f7 4 picks = 5 boxes per pick on average
At 330 cycles per hour = 5 boxes x 330 picks\/hour = 1650 boxes per hour<\/strong><\/p>\n\n\n\n

High-volume row picks like this show the power of multi-pick grippers and well-optimised stacking logic.<\/p>\n\n\n\n

<\/p>\n\n\n\n

What If the Robot Runs Faster?<\/strong><\/p>\n\n\n\n

In some cases\u2014particularly where boxes are lightweight, uniform, and the gripper is well optimised\u2014robotic palletisers can run at 400 picks per hour or more.<\/p>\n\n\n\n

Here\u2019s what that means for each example:<\/p>\n\n\n\n

\"\"<\/a><\/figure>\n\n\n\n

As you can see, the pick grouping and stacking pattern have a much bigger impact on throughput than the robot speed alone.<\/p>\n\n\n\n

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Key Takeaways<\/strong><\/p>\n\n\n\n