High-Mix Dairy Palletizing for Cases & Crates | RPC-MX Robotic Palletizer

High-mix dairy lines rarely run one package format for long. Corrugated cases, SRPs, reusable plastic crates, and changing pallet requirements can create end-of-line complexity when each format needs different handling, tooling, pallet patterns, and discharge flow. In this video, Pearson Packaging Systems showcases an RPC-MX robotic palletizing system designed to help manufacturers palletize cases and crates through one integrated end-of-line automation solution. The system supports high-mix dairy production by coordinating robotic picking, pallet handling, empty pallet supply, finished pallet discharge, and automated EOAT changeover inside a dual-robot palletizing cell. This RPC-MX application includes two robotic palletizing zones, dual product infeeds, zoned MDR conveyor staging, multi-case vacuum picking for RSC cases, clamp-style EOAT for reusable plastic crates, automated pallet dispensing, pallet discharge conveyors, FANUC M-410/140H robots, Allen-Bradley CompactLogix controls, and Pearson’s User Centric Design HMI. For dairy manufacturers, high pallet mix can create serious end-of-line challenges. Cases and crates may require different gripping methods, different pallet patterns, and different load-building strategies. This system is designed to keep mixed-format output moving by staging products before each pick, matching the EOAT to the package format, and building controlled pallet loads across both case and crate formats. Vacuum end-of-arm tooling picks multiple RSC cases per cycle to increase palletizing rate without adding extra pick cycles. Clamp tooling grips reusable plastic crates and places each crate to seat onto the crate below, helping close row-to-row gaps that can weaken load stability. Programmed pallet patterns guide layer placement, while controlled robot motion supports load quality from the base of the pallet through final placement. Automated pallet handling keeps the palletizing cycle moving. Pallet stacks load outside the guarded cell, empty pallets index into build position, finished loads discharge from the build zone, and new pallets queue for the next cycle. This helps reduce idle time between completed loads and keeps pallet exchange synchronized between builds. Quick automated EOAT exchange allows the robot to switch between vacuum and clamp tooling, helping cases and crates run through the same palletizing system. For manufacturers managing frequent format changes, this helps reduce changeover friction while supporting greater end-of-line flexibility. Pearson’s User Centric Design HMI supports operators through format changes, navigation, adjustments, and recovery. With guided changeover instructions and graphical fault recovery, the system is built for production environments where uptime, throughput, package flexibility, and finished load quality matter. For manufacturers evaluating robotic palletizing, this RPC-MX application demonstrates how one configurable robotic palletizing system can support high-mix production, multiple package formats, automated pallet flow, application-specific EOAT, controlled load building, and end-of-line flexibility. Video Timeline and Chapters 0:00 Pearson Packaging Systems 0:04 Dual-Robot RPC-MX Robotic Palletizing Cell 0:13 Pallet Stack Loading Outside the Guarded Cell 0:18 Empty Pallet Indexing Into Build Position 0:24 Dual Infeeds Staging Cases and Crates 0:29 Coordinated Robot Picks, Pallet Handling, and Discharge 0:38 Multi-Case Vacuum Picking for RSC Cases 0:43 Clamp Tooling for Reusable Plastic Crates 0:54 Programmed Pallet Patterns and Layer Building 1:06 Product Staging Before Each Robot Pick 1:10 Controlled Case Placement and Load Quality 1:22 Crate Seating and Row-to-Row Load Stability 1:35 Finished Case Pallet Discharge 1:41 Finished Load Reorientation 1:42 Crate Palletizing Alongside Case Palletizing 1:54 Finished Crate Load Discharge and Empty Pallet Queueing 2:03 Quick Automated EOAT Exchange 2:18 User Centric Design HMI and Guided Changeover Explore the equipment shown in this video: 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 #roboticpalletizer #dairypackaging #dairyautomation #packagingautomation #endoflineautomation #secondarypackaging #casepalletizing #cratepalletizing #foodpackagingautomation #manufacturingautomation