Dual Floor Robotic Palletizer | Continuous Pallet Changes, One Compact Cell

Most palletizers stop for pallet changes. This one works through them. In this video, Pearson Packaging Systems showcases a Dual Floor Robotic Palletizing Cell, a simple robotic palletizing solution that builds transport-ready pallet loads from multiple sealed case sizes. By pairing a single FANUC robot with two floor-level pallet build stations, the system maintains continuous operation during pallet changes while delivering multi-SKU flexibility within a compact footprint. This Dual Floor Robotic Palletizing Cell application includes: • FANUC robotic palletizing system • Vacuum end-of-arm tool with single and dual-pick capability • Zoned motor-driven roller case infeed • Pneumatic case crowder for case alignment and squaring • Dual floor-level pallet build stations • Zoned safety light curtains for pallet exchange during operation • Pearson User-Centric Design HMI • Recipe-based pallet patterns for multiple sealed case sizes How does the system keep running during pallet changes? The Dual Floor Cell uses two floor-level pallet build stations operating independently. While the robot builds on one pallet, an operator can remove a completed load and stage a new pallet at the adjacent station. Zoned safety light curtains isolate each station, allowing pallet changes to occur while palletizing continues. How does one palletizer handle multiple case sizes? Every case size is assigned to a stored recipe containing pallet patterns, layer counts, and robot pick behavior. Operators select the desired product through the HMI, and the robot automatically adjusts to the selected pallet configuration. How does changeover work? Changeovers are guided through Pearson's User-Centric Design HMI. Operators are walked through the process using intuitive icon-based screens, while recipe-driven controls simplify transitions between products. Graphical diagnostics and guided fault recovery help reduce downtime, improve operator independence, and minimize reliance on specialized training. For manufacturers looking for a straightforward way to automate palletizing across multiple products, the Dual Floor Robotic Palletizing Cell delivers continuous pallet changes, multi-SKU flexibility, and reliable robotic performance in a compact footprint. Video Timeline & Chapters 0:04 Dual Floor robotic palletizing cell 0:14 Multiple case sizes on the infeed 0:27 Pallet loading and case palletizing 0:50 FANUC robot serving two build stations 1:06 Case crowder squares each case 1:25 Dual pick on the smallest cases 1:50 Continuous pallet change with zoned light curtains 2:08 Guided changeover on the User-Centric Design HMI Explore the Equipment Dual Floor Robotic Palletizer https://pearsonpkg.com/equipment/robo... RPC-MX Configurable Robotic Palletizer https://pearsonpkg.com/equipment/robo... Explore Pearson Packaging Systems https://pearsonpkg.com/ Follow Pearson Packaging Systems LinkedIn:   / pearson-packaging-systems   YouTube:    / @pearsonpkg   Facebook:   / pearsonpkgsys   #RoboticPalletizing #PackagingAutomation #FANUC #EndOfLineAutomation #ManufacturingAutomation #SecondaryPackaging #PearsonPackaging