Automatic palletising: how to optimise logistics flows with scalable and mixed systems

The growth of e-commerce, the proliferation of formats and the need for ever faster processes are prompting companies to review their internal workflow management.

In this context, palletising has become one of the most strategic processes for increasing efficiency, quality and operational continuity.

From traditional solutions to fully automated palletising islands, right up to advanced mixed palletising logic, warehouses are evolving towards smarter, higher-performance models.

Palletising in the context of automated warehouses

In the past, palletising was a predominantly manual activity, not very scalable and subject to variability.

Today, thanks to integration with automatic palletising systems, collaborative robotics and intelligent software, it has become a key stage in ensuring high standards, reducing errors and improving transport efficiency.

In automated warehouses, palletising is no longer an isolated action, but part of a continuous flow that connects production lines, handling systems and shipping areas. This allows you to maintain a constant pace and increase production capacity without increasing the labour required.

Mixed palletising: the answer to growing complexity

One of the most important challenges for logistics management in automated warehouses is mixed palletisation, which has a direct impact on supplier-customer relationships: being able to assemble and deliver a mixed pallet correctly means reducing processing times and the number of shipments, and offering customers a flexible, high-quality service.

Today’s consumers demand ever greater product variety from businesses, delivered more quickly and at lower cost.

This trend translates into higher demand but lower prices and, consequently, more SKUs in less space and increased performance in terms of speed, security, flexibility and efficiency.

For sectors such as retail, large-scale distribution, cosmetics or food & beverage, where multiple formats and highly variable orders coexist, mixed palletising represents a decisive competitive advantage.

The software platforms automatically determine the best configuration, while the palletising robots perform the composition with consistent precision.

The result is greater operational flexibility and reduced preparation times for pallets destined for retail outlets or distribution centres.

Palletising islands: dedicated and scalable automation

Today, more and more companies are evolving from traditional systems to robotic palletising cells, compact and integrated solutions that completely automate pallet creation. These cells combine automatic palletisers, anthropomorphic robots, artificial vision, dedicated gripping systems and intelligent software, taking precision and repeatability to a higher level.

Palletising islands enable you to:

• handle different formats without mechanical modifications;
• increase productivity even on multiple lines simultaneously;
• improve safety by eliminating repetitive and risky manual operations;
• ensure uniform, stable pallets that are ready for shipping.

In a context of increasing product variability and the need for greater efficiency, palletising islands are a strategic choice for those who want to transform logistics into a competitive advantage.

These are scalable, integrated solutions that can be adapted to any warehouse layout, perfect for supporting the growth of your company.

Palletising and automation: an integrated ecosystem

When integrated with automatic handling systems and WMS software, palletising becomes a strategic hub for the entire logistics supply chain.

Automation reduces downtime, avoids bottlenecks and makes the entire plant more resilient and productive.

Conclusion

Palletising is no longer just a simple operational step, but a strategic element in ensuring continuity, precision and competitiveness.

Companies that adopt solutions such as mixed palletising, palletising islands and automated warehouses achieve more stable flows, higher finished product quality and optimised cost management.

Each mixed pallet is configured according to the most efficient palletising scheme, automatically generated by the software based on the type of order and destination.

Companies that invest in mixed systems, palletising islands and logistics automation reap benefits in terms of productivity, quality and savings. Investing in these technologies means building a more efficient, scalable logistics model that is ready to meet the challenges of the modern market.

Do you want to optimise palletising in your warehouse?
Discover how Errevi can help you design a tailor-made system with automatic palletisers, software and scalable layouts.