A Practical Guide to Robotic Palletising with FlexPal
As Bulgarian manufacturers continue to face labor shortages, rising production costs, and increasing customer demands, palletising remains one of the most common bottlenecks on the factory floor.
Many companies still rely on manual palletising, requiring operators to repeatedly lift, stack, and organize products throughout the day. While this approach may work for low volumes, it often creates challenges related to productivity, consistency, workplace safety, and labor availability.
This is where palletising automation can deliver immediate value.
Why Automate Palletising?
Palletising is one of the most repetitive and physically demanding tasks in manufacturing and logistics. Automated palletising systems use robots or collaborative robots (cobots) to pick products and place them onto pallets according to predefined patterns.
The benefits include:
- Increased productivity
- Consistent pallet quality
- Reduced labor costs
- Improved workplace safety
- Higher throughput
- Better use of available labor
Modern palletising systems can handle cartons, boxes, bags, KLT containers, and many other product types with high precision and repeatability. Automated palletising solutions also allow manufacturers to operate multiple shifts without increasing staffing levels. Robotec highlights these benefits as key drivers for adopting robotic palletizing solutions.
Common Palletising Challenges in Bulgarian Factories
Manufacturers across Bulgaria frequently encounter:
- Difficulty finding operators for repetitive manual work
- Employee turnover in logistics and packaging departments
- Inconsistent pallet quality
- Production bottlenecks at end-of-line operations
- Growing production volumes
These challenges are especially common in the food, beverage, pharmaceutical, consumer goods, automotive, and logistics sectors.
Introducing FlexPal
FlexPal is Robotec’s modular palletising system designed to automate both palletising and depalletising operations using collaborative robots. The system is available in multiple configurations to suit different production requirements.
Learn more:
FlexPal Robotic Palletising System
Unlike fully custom-built palletisers, FlexPal follows Robotec’s modular automation philosophy. This means faster implementation, lower engineering effort, and easier scalability.
FlexPal is part of the FlexLine portfolio, where each module is a predefined, reusable automation solution built on proven technology platforms.
FlexPal Configurations
FlexPal is available in several variants:
FlexPal A
Ideal for standard palletising applications.
- Pallet height up to 1500 mm
- Up to 10 boxes per minute
- mk profile structure
- Vertical telescopic column
FlexPal B
Designed for higher capacity operations.
- Pallet height up to 2500 mm
- Up to 20 Euro pallets
- Linear 7th axis
- Automatic or manual robot column
FlexPal C
A compact solution with extended pallet handling capabilities.
- Up to 20 Euro pallets
- Linear axis integration
- Modular expansion options
Specifications according to Robotec’s FlexPal product portfolio.
Which Universal Robots Model Should You Choose?
FlexPal can be implemented with different Universal Robots cobots depending on payload and application requirements. Robotec supports UR10, UR12e, UR16e, UR20, and UR30 configurations.
| Robot Model | Payload | Typical Application |
| UR10 | 10 kg | Small cartons and boxes |
| UR12e | 12.5 kg | General palletising |
| UR16e | 16 kg | Heavier packaging |
| UR20 | 25 kg | High-performance palletising |
| UR30 | 35 kg | Heavy-duty palletising |
Is FlexPal Suitable for Your Factory?
FlexPal is particularly suitable for:
- Food manufacturers
- Beverage producers
- Consumer goods companies
- Packaging facilities
- Logistics centers
- Warehouse operations
- Manufacturing plants with manual palletising processes
If your operators are currently spending hours stacking products manually, a robotic palletising solution may provide one of the fastest returns on investment in your automation journey.
Why Choose Robotec?
Robotec is a provider of modular automation solutions based on collaborative robots, conveyor systems, and proprietary automation architectures.
The company owns the cell concepts, module architectures, and solution designs while execution is performed through a qualified partner network.
This allows customers to benefit from:
- One point of contact
- Proven modular solutions
- Faster implementation
- Lower project risk
- Scalable automation systems
Conclusion
For Bulgarian manufacturers looking to improve productivity and reduce dependence on manual labor, palletising automation represents one of the most effective investments available today.
With its modular architecture, collaborative robot technology, and proven deployment model, FlexPal enables companies to automate palletising quickly and efficiently while maintaining flexibility for future growth.
Learn more about FlexPal: https://www.robotec.bg/flexpal/
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