{"id":3043,"date":"2026-08-06T13:21:04","date_gmt":"2026-08-06T13:21:04","guid":{"rendered":"https:\/\/www.granta-automation.co.uk\/news\/?p=3043"},"modified":"2026-08-06T13:51:00","modified_gmt":"2026-08-06T13:51:00","slug":"case-study-automating-the-palletising-of-insulation-batts-with-the-granta-cobot-palletiser","status":"publish","type":"post","link":"https:\/\/www.granta-automation.co.uk\/news\/case-study-automating-the-palletising-of-insulation-batts-with-the-granta-cobot-palletiser\/","title":{"rendered":"Case Study: Automating the Palletising of Insulation Batts with the Granta Cobot Palletiser"},"content":{"rendered":"\n<p><strong>Sector:<\/strong> Manufacturing \u2013 passive fire protection \/ fire-stopping products<br><strong>Application:<\/strong> End-of-line palletising of insulation batts<br><strong>Solution:<\/strong> Granta Cobot Palletiser<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><a href=\"https:\/\/www.granta-automation.co.uk\/news\/wp-content\/uploads\/2026\/08\/testimonial.png\"><img loading=\"lazy\" decoding=\"async\" width=\"897\" height=\"598\" src=\"https:\/\/www.granta-automation.co.uk\/news\/wp-content\/uploads\/2026\/08\/testimonial.png\" alt=\"Granta cobot palletiser stacking insulation batts\n\" class=\"wp-image-3044\" srcset=\"https:\/\/www.granta-automation.co.uk\/news\/wp-content\/uploads\/2026\/08\/testimonial.png 897w, https:\/\/www.granta-automation.co.uk\/news\/wp-content\/uploads\/2026\/08\/testimonial-300x200.png 300w, https:\/\/www.granta-automation.co.uk\/news\/wp-content\/uploads\/2026\/08\/testimonial-768x512.png 768w\" sizes=\"auto, (max-width: 897px) 100vw, 897px\" \/><\/a><\/figure>\n\n\n\n<p><strong>Overview<\/strong><\/p>\n\n\n\n<p>A UK manufacturer of fire-stopping products set out to automate the palletising of insulation batts at the end of one of their production lines. The packs were being hand-stacked by operators in a pre-defined pattern \u2014 a process that was physically demanding, inconsistent in speed, and capping the line&#8217;s true output.<\/p>\n\n\n\n<p>Granta Automation supplied a <a href=\"https:\/\/www.granta-automation.co.uk\/types-of-automation\/cobot-palletiser\" title=\"\">Cobot Palletiser<\/a>: a compact, collaborative system that now stacks every pallet to an identical, repeatable standard, removes the manual handling, and gives the line a reliable, consistent output it didn&#8217;t have before.<\/p>\n\n\n\n<p><strong>The Challenge<\/strong><\/p>\n\n\n\n<p>At the end of the line, production operators stood and manually stacked packs onto pallets for despatch, following a pre-defined stack pattern. While it worked, the manual approach carried three persistent problems:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Health and safety risk.<\/strong> Repetitive manual handling and lifting exposed operators to the risk of repetitive strain injury (RSI) and other injuries.<\/li>\n\n\n\n<li><strong>Inconsistent output speed.<\/strong> Because stacking depended on individual operators, the pace varied \u2014 which made line output unpredictable and constrained overall throughput.<\/li>\n\n\n\n<li><strong>Variable stack quality.<\/strong> With pallets built by hand, consistency came down to the individual, leaving room for stacking errors that can cause problems further down the supply chain.<\/li>\n<\/ul>\n\n\n\n<p>The business wanted to reduce the risk of injury to its people, increase line output productivity, and put the end-of-line process onto a more reliable, repeatable footing.<\/p>\n\n\n\n<p><strong>Building the Business Case<\/strong><\/p>\n\n\n\n<p>Before committing, the customer worked through a full <em>cost of not automating<\/em> analysis with Granta \u2014 looking well beyond the obvious. The exercise weighed up the factors that quietly erode margin when an end-of-line process is left manual, including:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Production reliability and running time<\/strong> \u2014 the value lost to variable pace and stoppages across shifts.<\/li>\n\n\n\n<li><strong>Faster production<\/strong> \u2014 the additional output value unlocked once the line is no longer paced by hand-stacking.<\/li>\n\n\n\n<li><strong>Defective product<\/strong> \u2014 damage and stacking-quality issues that create problems in transport and storage.<\/li>\n\n\n\n<li><strong>Health and safety<\/strong> \u2014 the cost of absence, claims and HR challenges tied to manual handling and RSI.<\/li>\n\n\n\n<li><strong>Reliability and resourcing<\/strong> \u2014 the cost and difficulty of recruiting and covering manual roles.<\/li>\n<\/ul>\n\n\n\n<p>Importantly, the strongest return wasn&#8217;t a single line item \u2014 it was the cumulative effect. As Granta consistently sees across installations, the biggest payback comes from an uplift in production combined with the intangible gains: fewer H&amp;S issues, reduced HR burden and improved staff morale. Because an automated cell holds a steady takt time \u2014 it doesn&#8217;t take breaks, call in sick or pause for conversations \u2014 customers typically see a 30%+ increase in production throughput they hadn&#8217;t even priced into the business case.<\/p>\n\n\n\n<p>This case also reframed the role of the team. Rather than being about removing people, automation removed a repetitive, physically demanding task \u2014 freeing operators from injury-prone manual handling and allowing that effort to be redirected to more skilled, higher-value work.<\/p>\n\n\n\n<p><strong>The Solution: The Granta Cobot Palletiser<\/strong><\/p>\n\n\n\n<p>Granta recommended its <strong>Cobot Palletiser<\/strong> \u2014 a high-payload collaborative robot ideally suited to a line where space is tight and consistency matters. Key reasons it fit this application:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Small footprint.<\/strong> A compact, self-contained cell that slots into a constrained end-of-line space without a major reorganisation.<\/li>\n\n\n\n<li><strong>High payload.<\/strong> A genuinely high weight-load capability, comfortably handling the packs coming off the line.<\/li>\n\n\n\n<li><strong>Genuinely simple programming.<\/strong> Granta&#8217;s easy-programming software lets operators set up and adjust stack patterns themselves \u2014 no specialist robot programmer required.<\/li>\n\n\n\n<li><strong>Efficient, built-in safety systems.<\/strong> Collaborative safety features allow the system to work safely in a shared, space-constrained environment.<\/li>\n\n\n\n<li><strong>A cost-effective package.<\/strong> High capability and consistency without the cost or complexity of a large conventional palletising installation.<\/li>\n<\/ul>\n\n\n\n<p><strong>The Results<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Every pallet is now identical.<\/strong> Stack quality no longer depends on the individual \u2014 the system guarantees the same result every time, every shift.<\/li>\n\n\n\n<li><strong>Manual handling removed<\/strong> from the end of the line, sharply reducing the risk of RSI and lifting injuries.<\/li>\n\n\n\n<li><strong>Reliable, consistent output.<\/strong> A steady, automated takt time replaces operator-to-operator variation, lifting and stabilising line productivity.<\/li>\n\n\n\n<li><strong>A future-proofed line.<\/strong> Simple in-house reprogramming means the system can adapt as pack patterns and requirements change.<\/li>\n<\/ul>\n\n\n\n<p><strong>The Investment and the Return<\/strong><\/p>\n\n\n\n<p>Set against the cost of running the line manually, the payback was rapid. Granta&#8217;s cost-of-automation analysis showed the complete solution \u2014 palletising system plus operator training \u2014 paying for itself in under five months, with a significant net return in every year that followed.<\/p>\n\n\n\n<p>That&#8217;s before accounting for the harder-to-quantify benefits: improved safety, consistently high stack quality and reliable, predictable output.<\/p>\n\n\n\n<p><strong>In the Customer&#8217;s Words<\/strong><\/p>\n\n\n\n<p><em>&#8220;I chose the Cobot palletiser from Granta because it has a very small footprint and a very high weight load. The system is very easy to use \u2014 programming is unbelievably simple. On the quality side, I can now guarantee that every pallet is the same when it leaves this factory, whereas before it was down to individuals. I&#8217;d recommend the Cobot system for its small footprint, high weight load, unbelievably efficient safety systems, and because it&#8217;s a genuinely cost-effective solution.&#8221;<\/em><\/p>\n\n\n\n<p>\u2014 Production Manager at a Fire Stopping Products Manufacturer<\/p>\n\n\n\n<p><strong>Could the Cobot Palletiser work for your line?<\/strong><\/p>\n\n\n\n<p>If hand-stacking is putting your people at risk or making your output unpredictable, the Granta Cobot Palletiser offers a compact, high-payload, easy-to-program route to consistent, reliable palletising \u2014 and a business case that usually pays back faster than expected.<\/p>\n\n\n\n<p>Book a free site visit today &#8211; 01223 499488 or <a href=\"mailto:helpline@granta-automation.co.uk\">helpline@granta-automation.co.uk<\/a><\/p>\n\n\n<p><!-- \/wp:paragraph --><\/p>\n<div class=\"topbutton\"><a href=\"\/contact\">contact us<\/a><\/div>\n<p><!-- Whiteblock Bottom--><\/p>\n<div id=\"w2\" class=\"whiteblock2\">\n<div class=\"wpwhiteblockwv\">\n<p><span style=\"font-size: large;\"><b>Watch automation videos&#8230;<\/b><\/span><\/p>\n<p><a href=\"\/watch-videos\"><img decoding=\"async\" title=\"Watch Automation Videos\" src=\"\/images\/video-image.jpg\" alt=\"Watch\" width=\"300px\" \/><\/a><\/p>\n<\/div>\n<div class=\"wpwhiteblockwv\">\n<p><span style=\"font-size: large;\"><b>Find out more&#8230;<\/b><\/span><\/p>\n<ul>\n<li><a href=\"\/news\/is-your-warehouse-slowing-down-how-to-spot-hidden-bottlenecks-in-packing-and-shipping\/\">Is Your Warehouse Slowing Down? How to Spot Hidden Bottlenecks in Packing and Shipping<\/a><\/li>\n<li><a href=\"\/news\/the-granta-advantage-kuka-platinum-status-patented-software-smarter-automated-palletising\/\">The Granta Advantage:\u00a0 KUKA Platinum Status + Patented Software = Smarter Automated Palletising<\/a><\/li>\n<li><a href=\"\/news\/why-granta-palletisers-are-the-preferred-choice-for-contract-packers\/\">Why Granta Palletisers are the Preferred Choice for Contract Packers<\/a><\/li>\n<li><a href=\"\/news\/5-ways-automation-can-solve-the-uks-manufacturing-labour-shortage\/\">5 Ways Automation Can Solve the UK\u2019s Manufacturing Labour Shortage<\/a><\/li>\n<li><a href=\"\/news\/the-compact-palletiser-big-performance-in-a-small-footprint\/\">The Compact Palletiser: Big Performance in a Small Footprint<\/a><\/li>\n<\/ul>\n<\/div>\n<\/div>\n<div class=\"wppaltypes\">\n<div class=\"circle\"><a href=\"\/types-of-automation\/robotic-palletising\/palletiser-application-examples\/bag-palletiser\"> <img decoding=\"async\" title=\"Bag Palletiser\" src=\"\/images\/paltypes\/Bag-Palletiser-2-Lane-c.png\" alt=\"Bag Palletiser\" width=\"160px\" \/><\/a>Bag Palletiser<\/div>\n<div class=\"circle\"><a href=\"\/types-of-automation\/robotic-palletising\/palletiser-application-examples\/barrel-palletiser\"> <img decoding=\"async\" title=\"Barrel Palletiser\" src=\"\/images\/paltypes\/barrel-palletiser-c.png\" alt=\"Barrel Palletiser\" width=\"160px\" \/><\/a>Barrel Palletiser<\/div>\n<div class=\"circle\"><a href=\"\/types-of-automation\/robotic-palletising\/palletiser-application-examples\/box-palletiser\"> <img decoding=\"async\" title=\"Box Palletiser\" src=\"\/images\/paltypes\/Box-Palletiser-2-Lane.png\" alt=\"Box Palletiser\" width=\"160px\" \/><\/a>Box Palletiser<\/div>\n<div class=\"circle\"><a href=\"\/types-of-automation\/robotic-palletising\/palletiser-application-examples\/crate-palletiser\"> <img decoding=\"async\" title=\"Crate Palletiser\" src=\"\/images\/paltypes\/Crate-Palletiser-2-Lane.png\" alt=\"Crate Palletiser\" width=\"160px\" \/><\/a>Crate Palletiser<\/div>\n<div class=\"circle\"><a href=\"\/types-of-automation\/robotic-palletising\/palletiser-application-examples\/tray-palletiser\"> <img decoding=\"async\" title=\"Tray Palletiser\" src=\"\/images\/paltypes\/Tray-Palletiser-c.png\" alt=\"Tray Palletiser\" width=\"160px\" \/><\/a>Tray Palletiser<\/div>\n<\/div>\n<p><!-- \/wp:paragraph --><\/p>\n<p><!-- wp:paragraph --><\/p>\n<p><!-- \/wp:paragraph --><\/p>","protected":false},"excerpt":{"rendered":"<p>Sector: Manufacturing \u2013 passive fire protection \/ fire-stopping productsApplication: End-of-line palletising of insulation battsSolution: Granta Cobot Palletiser Overview A UK manufacturer of fire-stopping products set out to automate the palletising of insulation batts at the end of one of their &hellip; <a href=\"https:\/\/www.granta-automation.co.uk\/news\/case-study-automating-the-palletising-of-insulation-batts-with-the-granta-cobot-palletiser\/\">Continue reading <span class=\"meta-nav\">&rarr;<\/span><\/a><\/p>\n","protected":false},"author":2,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[296,332,422,61,96,463,212,237,255,186,455],"tags":[326,625],"class_list":["post-3043","post","type-post","status-publish","format-standard","hentry","category-automated-palletising","category-box-palletiser","category-cobot-palletiser","category-company-news","category-updates","category-palletiser-2","category-palletiser","category-palletising","category-robotic-palletiser","category-robotic-palletising","category-small-palletiser","tag-cobot-palletiser","tag-cobot-palletiser-case-study"],"aioseo_notices":[],"_links":{"self":[{"href":"https:\/\/www.granta-automation.co.uk\/news\/wp-json\/wp\/v2\/posts\/3043","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.granta-automation.co.uk\/news\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.granta-automation.co.uk\/news\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.granta-automation.co.uk\/news\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.granta-automation.co.uk\/news\/wp-json\/wp\/v2\/comments?post=3043"}],"version-history":[{"count":3,"href":"https:\/\/www.granta-automation.co.uk\/news\/wp-json\/wp\/v2\/posts\/3043\/revisions"}],"predecessor-version":[{"id":3047,"href":"https:\/\/www.granta-automation.co.uk\/news\/wp-json\/wp\/v2\/posts\/3043\/revisions\/3047"}],"wp:attachment":[{"href":"https:\/\/www.granta-automation.co.uk\/news\/wp-json\/wp\/v2\/media?parent=3043"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.granta-automation.co.uk\/news\/wp-json\/wp\/v2\/categories?post=3043"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.granta-automation.co.uk\/news\/wp-json\/wp\/v2\/tags?post=3043"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}