Dual-Station Robotic Palletizer

Product Description

The SunAura dual-station robotic palletizer is a mid-to-high throughput end-of-line cell built around one proven idea: never stop the robot to change a pallet. A single 4-axis robot with 50kg payload and 2000mm reach works between two independent pallet stands mounted on roller conveyors. When one pallet reaches its programmed height, the robot simply shifts its stacking target to the second station while the first pallet is rolled out and replaced. The production line keeps running, and the 12 cycles-per-minute output is never lost to a pallet swap.

Cases arrive from the packaging line on a powered roller conveyor with side guides and a centering device. A vacuum or mechanical gripper EOAT (matched to your product) picks each case and builds the chosen pallet pattern — interlocking brick, column, or pinwheel — layer by layer under PLC control. The HMI stores dozens of recipes, so operators can select a product by name rather than re-teach points. Because this is a fast-moving industrial robot rather than a collaborative cobot, the cell comes complete with interlocked safety fencing and a light-curtain access gate to keep people out of the work envelope during operation.

Powered by 380V 3-phase supply, the cell is engineered for food & beverage, consumer goods, and distribution centers running multiple shifts. Every unit undergoes a 48-hour continuous run test before shipment and ships CE certified. Send us your carton samples, pallet size and conveyor height — our engineers will design the infeed/outfeed and pattern around your existing line.

Technical Specifications

Key Features & Benefits

• Zero downtime for pallet changeover: Two pallet positions let operators swap a full pallet while the robot keeps stacking on the second station — the key advantage over a single-pallet cell.
• High 12 cycles-per-minute throughput: A purpose-built 4-axis palletizing arm with 50kg payload and 2000mm reach keeps pace with medium-to-high speed case lines.
• Recipe-driven pattern library: Store dozens of carton sizes and pallet patterns on the HMI. Operators select the product name and press start — no re-programming between SKUs.
• Safety fencing and light curtain included: The interlocked fence and access gate keep staff out of the robot envelope while running; the robot stops instantly if the gate opens.
• Powered roller infeed with centering: Cases arrive squared and centered, so every pick is accurate — fewer drops and cleaner layers.
• Flexible EOAT: Vacuum gripper for rigid cartons and trays; mechanical gripper for bags and rigid packs. Quick tool changeover supports mixed product on one cell.
• 380V 3-phase industrial duty: Built for multi-shift, 5–6 day/week operation in food, consumer goods and distribution environments.

Application Industries

Load compatibility: Rigid cartons, trays, shrink-wrapped packs and light bags up to 50kg per pick. For 120–180kg heavy bags, see our heavy-duty robotic range.

How the Dual-Station Palletizer Works

The dual-station design is what makes this cell productive. The robot never waits on a pallet swap because it always has a second empty pallet waiting:

1. Cases arrive on the roller conveyor. Powered rollers carry cases from the packaging line; side guides and a centering device square each case at the pick station.
2. EOAT picks the case. The vacuum or mechanical gripper descends, secures the case, and the robot lifts it clear of the conveyor.
3. Robot places it on the active pallet. The 4-axis arm moves to the currently selected station (A or B) and places the case in the next position of the stored pallet pattern.
4. Station A fills — robot switches to Station B. When station A reaches its programmed layer/pallet count, the HMI signals the robot to target station B. Station A goes into “pallet ready” status.
5. Full pallet rolled out, empty rolled in — robot keeps running. An operator or forklift swaps the full pallet at station A while the robot keeps stacking uninterrupted on station B. Once A is reloaded with an empty pallet, the cycle continues.

Is This the Right Palletizer for You?

This dual-station cell is the right fit if your operation matches all four of the following. If you fall outside any of them, our team can recommend a different SunAura model:

1. Single loads up to 50kg: This arm handles cartons and bags in the 10–50kg range. If you routinely palletize 120–180kg heavy bags or drums, choose the 120kg or 180kg heavy-duty robots instead.
2. Throughput around 10–12 cases/min and growing: The dual station shines when losing even a minute per pallet swap costs you meaningful output. If your line is slower and single-operator, a collaborative or compact cell may be more economical.
3. You need continuous, non-stop operation: The whole point of dual stations is no downtime during changeover. If you can tolerate periodic stops to swap pallets, a single-pallet robot or low-level layer palletizer can lower capital cost.
4. You have floor space for a fenced cell and 3-phase power: This is an industrial robot behind safety fencing on 380V 3-phase. If you need an unfenced, single-phase, small-footprint solution, our collaborative cobot is the better fit.

Troubleshooting Guide — Common Issues & Solutions

Dual-station cells are reliable, but the extra conveyor and two-station logic introduce their own failure modes. Below are the most common problems we diagnose remotely. Always lock out and tag out energy before entering the fenced cell.

If the issue persists after trying these steps, email photos and a short 10-second video to [email protected] — our engineers usually diagnose the root cause within one business day.

Frequently Asked Questions

Related Palletizers

Four-Axis Robotic Palletizer (120kg)

High-Level Layer Palletizer

Collaborative Robot Palletizer System

Low-Level Case Palletizer

Browse the full range on the palletizers landing page. Also explore our induction sealers and filling machines to build a complete packaging line.