What Is a Cobot Palletizer? A Practical Guide to the AUBO Palletizer
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A cobot palletizer is a collaborative robot that picks cases off the end of a line and stacks them onto pallets in a set pattern. It takes over one of the most repetitive, physically demanding jobs in a plant, in a compact footprint.
The AUBO Palletizer from AUBO Robotics USA comes in two forms: a full Palletizing Workstation with a built-in lift, and a simpler Palletizing Robot on a pedestal. Both run on AUBO iS Series cobots with payloads from 20 to 35 kg.
This guide explains when a cobot palletizer makes sense, how the two versions differ, and which model fits your pallets and products.
When Does a Cobot Palletizer Make Sense?
A cobot palletizer fits best where cases arrive at a steady pace and people are stacking them by hand. It is built for plants that need end-of-line automation without a large conventional palletizing system.
It is usually a strong fit if you have:
- Steady, single-pick case flow of up to about 8.5 to 9 boxes per minute.
- Cases up to 35 kg, depending on the model and gripper.
- Standard pallets up to 48 x 48 in, which covers the common 48 x 40 in North American pallet.
- Tight floor space near the end of the line.
- Frequent product or pattern changes, since new pallet patterns are created on screen.
AUBO’s Palletizer is already in use in food and beverage, pharmaceuticals, home appliances and household chemicals.
Very high-speed lines may still need a conventional palletizer. Custom multi-pick configurations are available, so ask about your rate before ruling it out.
Palletizing Workstation vs. Palletizing Robot: Which Do You Need?
The key difference is the lift. The Workstation raises the cobot as the stack grows, so it reaches taller pallets. The Palletizing Robot is the basic version: the same kind of arm on a fixed pedestal, with no lift.
Dual pallet stations keep the line moving. The Workstation has a pallet position on each side. It fills one pallet while an operator swaps the full one on the other side, so palletizing doesn’t stop for pallet changes.
| Palletizing Workstation | Palletizing Robot | |
|---|---|---|
| Mounting | Enclosed workstation with built-in lift | Fixed pedestal with separate control cabinet |
| Models | iS20, iS20L, iS25, iS35 | 20 kg and 35 kg |
| Payload | 20 to 35 kg / 44.1 to 77.2 lb | 20 or 35 kg / 44.1 or 77.2 lb |
| Max palletizing height | 2,300 mm / 90.6 in (up to 2,800 mm / 110 in on iS35) | 2,000 mm / 78.7 in |
| Best for | Taller stacks and a turnkey, plug-and-play cell | Lower stacks and simpler applications |
Choose the Workstation if your loads stack above about 2 m (6.5 ft), or if you want the most complete cell. Choose the Palletizing Robot if your stacks stay lower and you want a simpler setup.
AUBO Palletizing Workstation Models Compared
The four Workstation models share the same ±0.05 mm repeatability and single-phase 220V power. They differ mainly in payload, reach and stack height.
| Spec | iS20 | iS20L | iS25 | iS35 |
|---|---|---|---|---|
| Payload | 20 kg / 44.1 lb | 20 kg / 44.1 lb | 25 kg / 55.1 lb | 35 kg / 77.2 lb |
| Robot reach | 1,647 mm / 64.8 in | 2,000 mm / 78.7 in | 1,700 mm / 66.9 in | 2,100 mm / 82.7 in |
| Palletizing height | 2,300 mm / 90.6 in | 2,300 mm / 90.6 in | 2,300 mm / 90.6 in | Up to 2,800 mm / 110 in |
| Max pallet size | 48 x 48 in | 48 x 48 in | 48 x 48 in | 51 x 51 in |
| Workstation footprint | 33.1 x 70.2 in | 33.1 x 70.2 in | 33.1 x 70.2 in | 35.4 x 70.2 in |
| Lift stroke | 750 mm / 29.5 in | 750 mm / 29.5 in | 750 mm / 29.5 in | Up to 500 mm / 19.7 in |
| Cycle time* | Up to 9 boxes/min | Up to 9 boxes/min | Up to 9 boxes/min | Up to 8.5 boxes/min |
| Total weight | 1,080 lb / 490 kg | 1,080 lb / 490 kg | 1,080 lb / 490 kg | 1,323 lb / 600 kg |
*Cycle time is based on single-pick operation and varies by application.
For most 20 kg cases, the iS20 is the starting point. The iS20L adds reach for wider patterns, and the iS35 handles the heaviest cases, largest pallets and tallest stacks. All models operate from 32 to 122°F (0 to 50°C).
Robotic Palletizing Without Programming
Traditional robotic palletizing often needs a programmer for every new product. The AUBO Palletizer replaces that with on-screen setup.
- One-click pattern generation: operators enter the pallet and case details, and the system generates the stacking pattern.
- New projects in under 1 minute: a new product or pattern can be set up in about a minute, with no code.
- Pre-configured cell: the Workstation arrives prewired and configured, so it can be deployed in under a day.
The cell also connects to the equipment you already run. It supports Modbus-RTU/TCP, TCP/IP and EtherNet/IP, and its compact design makes it easy to relocate when lines change.
Built-in safety features
- 10 levels of collision detection.
- Automatic arm locking during a power failure.
- 8 dedicated safety I/O ports to support all required safety functions.
As with any cobot, plan a risk assessment for your application. Depending on the results, a collaborative palletizer can reduce or eliminate the need for costly fencing.
Choosing End-of-Arm Tooling for Your Palletizing Cobot
The right gripper depends on your cases. AUBO offers four standard end-of-arm tools for the palletizing cobot, and custom sizes are available for most.
| Tool | Standard size | Weight | Compatible models | Good for |
|---|---|---|---|---|
| Rubber suction cup | 260 x 200 mm / 10.2 x 7.9 in | 5 kg / 11 lb | iS20, iS20L, iS25, iS35 | Smooth, sealed cartons |
| Foam suction cup | 260 x 200 mm / 10.2 x 7.9 in | 5 kg / 11 lb | iS20, iS20L, iS25, iS35 | Uneven or textured surfaces |
| Split suction cup | 300 or 350 mm long, 80 or 130 mm wide (4 sizes) | 7 kg / 15.4 lb | iS20, iS20L, iS25, iS35 | Avoid issues caused by tape and central gap |
| Clamp-type gripper | 540 x 260 x 396 mm / 21.3 x 10.2 x 15.6 in | 14 kg / 30.9 lb | iS35 | Heavier open top cases |
Remember that the gripper’s weight counts against the payload. A 14 kg clamp on a 35 kg arm leaves less capacity for the case, so size the tool and the model together.
ROI, Uptime and U.S. Support
As a turnkey cell, the AUBO Palletizer needs minimal design and integration work, and it fits existing plant layouts and workflows. AUBO estimates the investment is typically recovered in under a year, depending on the application.
Uptime is built into the design:
- Modular joints can be replaced in under 30 minutes.
- Minimal routine maintenance keeps downtime low.
- A full spare parts inventory is stocked in the U.S. for fast turnaround.
Support comes from AUBO Robotics USA in Romulus, Michigan, home to its warehouse, service department, training center and technical support team.
Cobot Palletizer FAQs
What is a cobot palletizer? A cobot palletizer is a collaborative robot that picks cases from a conveyor and stacks them on a pallet in a programmed pattern. It is typically more compact than a conventional palletizer, and it is designed to work near people after a risk assessment.
How much can the AUBO Palletizer lift? Payloads range from 20 kg (44.1 lb) on the iS20 and iS20L to 35 kg (77.2 lb) on the iS35. The gripper’s weight counts against that payload.
How high can it stack? The Palletizing Workstation stacks up to 2,300 mm (90.6 in), or up to 2,800 mm (110 in) with the iS35. The pedestal-mounted Palletizing Robot stacks up to 2,000 mm (78.7 in).
How fast is it? Up to 9 boxes per minute on the iS20, iS20L and iS25, and up to 8.5 boxes per minute on the iS35, based on single-pick operation. Custom multi-pick configurations are available.
Do operators need programming skills? No. Operators enter pallet and case details, and the system generates the stacking pattern. New projects can be created in under a minute.
Does it need safety fencing? It depends on your application and risk assessment. A collaborative palletizer can reduce or eliminate the need for costly fencing in many cases, and 8 dedicated safety I/O ports support the required safety functions.
Will it connect to my existing line? Yes. It supports Modbus-RTU/TCP, TCP/IP and EtherNet/IP, and it fits existing plant layouts and workflows.
Does the line stop when a pallet is full? Not with the Palletizing Workstation. It has a pallet station on each side, so it keeps stacking on one pallet while an operator swaps out the full one.
How long does installation take? The Palletizing Workstation arrives prewired and pre-configured, so it can be deployed in under a day. Creating a new pallet pattern after that takes under a minute.
See the AUBO Cobot Palletizer Run
A cobot palletizer takes repetitive lifting off your team and keeps stacks consistent, without a large guarded system. Choose the Workstation for taller stacks and a turnkey cell, or the Palletizing Robot for a simpler setup.
The fastest way to check fit is to see it stack your own cases. Book a Palletizer demo at our Romulus, Michigan training center, or download the Palletizer brochure for full specifications.
Automating welding too? Read our guide to cobot welding with SwitchWeld.