APPLICATION

Palletizing and case-packing

End-of-line stacking. Cobot picks finished cases from a conveyor and stacks to pallet pattern. Replaces stand-up operator work that's hard to staff.

Installed cell cost

$60-$160K

Payback (dual-shift)

10-18 mo

Payback (24/7 best-case)

8-14 mo

Leading cobots

4 models

01 / OPERATIONAL SHAPE

What this application actually is.

Palletizing is the cobot category's fastest-growing application in 2025-2026, driven by tight labour markets for stand-up shift work. Cells pick cases (typically 5-25 kg) from a conveyor and stack to a programmed pallet pattern. Throughput typically 5-12 cases per minute. Cobot palletizing cells are visibly easier to justify than machine tending in 2026 because (a) the displaced operator role is increasingly hard to staff, and (b) Robotiq's Palletizing Solution and FANUC's PalletPRO PRP software reduce programming time from weeks to days. The cohort sweet spot is UR20 / FANUC CRX-25iA / Doosan H2515 at 20-25 kg payload, with UR10e covering lighter case work.

02 / LEADING COBOTS FOR THIS APPLICATION

Which cobot fits, and why.

01Universal Robots UR20

20 kg · 1750 mm · $65,000-85,000

Robotiq Palletizing Solution is URCap-native; UR20 + Robotiq is a near-turnkey palletizing cell. Faster cycle times than UR16e at same Solution licence.

02FANUC CRX-25iA

25 kg · 1889 mm · $60,000-85,000

PalletPRO PRP software is FANUC-native and covers most pallet patterns out-of-box. 8-year service moat compounds at multi-shift palletizing.

03Universal Robots UR10e

12.5 kg · 1300 mm · $45,000-60,000

Lighter cases (5-12 kg). URCap palletizing software has more pre-validated configs for this payload bracket than any other cohort vendor.

04Doosan Robotics H2515

25 kg · 1500 mm · $60,000-75,000

Cost-sensitive alternative for the 20-25 kg bracket. Trade-off is North American integrator depth versus UR / FANUC.

03 / THE KILLER LINE ITEM

The cost most buyers underestimate.

Pallet-stack handling + conveyor integration

$25,000-$60,000

The cobot is half the cell. Pallet positioning, empty-pallet feed, stretch wrap, conveyor infeed — these add up fast. Most buyers underestimate this line by 30-50% on first quote.

04 / NO-PAYBACK FAILURE MODES

How palletizing and case-packingcells don't earn back.

Single-pallet cells without buffer

If the cobot pauses to wait for an empty pallet, throughput collapses. Buffer pallet stations are non-negotiable.

Mixed case sizes without vision

Variable case dimensions need 3D vision ($15-35K) or upstream sorting. Cells that try to handle 2+ case sizes without it stall on pattern conflicts.

Cobot cycle time at human-equivalent

Cobot palletizing is typically 5-12 cases/min. A skilled operator runs 12-18 cases/min on light cases. Payback math requires honest cycle comparison.

OTHER APPLICATIONS

Machine tending (CNC load / unload)Welding (MIG / TIG)Quality inspection Assembly and dispensing

Source: https://amdmachines.com/blog/cobot-payback-period/ · Verified 2026-06-03 · BLS-anchored wage data, AMD Machines + Robotomated 2026 integrator cost ranges.