The challenge
Apple packhouses require fast, reliable palletising systems that can handle high volumes without compromising product quality. Telescopic two-piece apple cartons, in particular, demand careful handling to prevent compression damage while maintaining efficient throughput during peak harvest periods.
A Hawkes Bay Packhouse identified the need for a compact, modular palletising solution capable of handling multiple SKUs simultaneously, while integrating safely into existing packhouse environments and meeting AS/NZS 4024 machine safety standards.
Our solution
The Cobot Palletiser was initially designed to meet the specific demands of apple packhouses, delivering gentle handling and precise stacking of apple Z pack cartons.
Each modular cell is capable of palletising two pallets simultaneously, supporting up to two concurrent SKUs at rates of up to 300 cartons per hour per cell, all while occupying minimal floor space.
Robotic tooling has been optimised for telescopic two-piece cartons to ensure secure handling and consistent stack quality. Alternative tooling configurations are also available on request, allowing the system to accommodate crates and varying carton sizes.
Zero-pressure DC infeed roller conveyors regulate product flow into the cell, supporting smooth operation and reducing the risk of carton damage. The complete system is designed to comply with AS/NZS 4024 machine safety standards, ensuring safe integration into operational packhouse environments. These DC rollers provide a safer method of conveying products than traditional belt Driven Conveyors.
The results
The Cobot Palletiser provides packhouses with a flexible, space-efficient palletising solution that balances throughput with product care.
By combining dual-pallet capability, modular design and safety-compliant engineering, the system enables consistent stacking performance, reduced manual handling and improved operational efficiency during peak production periods.