Robotic Depalletizing for Steel Pails: Maximizing Space and Flexibility
An industrial coatings manufacturer needed an automated solution to improve the efficiency and throughput of their container handling process. The challenge was to depalletize two distinct types of 5-gallon steel pails, nested open-head and tight head designs, within a limited footprint, while feeding a downstream filling line.
The automation solution needed to address several operational requirements:- Support two different pail formats with quick changeover between runs
- Maintain a consistent depalletizing rate to meet production demand
- Minimize the system footprint to preserve valuable floorspace
- Integrate with an existing filling operation
- Reduce manual labor involved in pail, dunnage, and pallet handling
Customer’s Challenge
The customer’s primary challenge was finding a solution that could fit within a defined footprint while handling multiple types of incoming containers required for their filling operation. Traditional hard automation lacked the flexibility to manage both open-head and tight head pails without additional equipment or dedicated floor space. By integrating robotics, the manufacturer was able to meet these needs with a compact, adaptable system. This mirrors challenges seen in other packaging environments—such as case erecting—where space-saving robotic solutions offer greater versatility compared to fixed automation. Read our related case study here:
System Description
The system is built around a FANUC M-410iB/140H palletizing robot. Operators load up to five full pallets of a single pail type onto an infeed conveyor. After selecting the pail type and quantity from the HMI, the robot automatically selects the appropriate program and end-of-arm tool configuration to begin depalletizing.
For tight head pails, the robot uses a vacuum-style gripper to pick two pails at once from adjacent stacks and place them on a dedicated conveyor for direct transfer to the filling room. For open-head nested pails, the robot lifts stacks of five pails using a specialized gripper with side forks. These stacks are sent to a Heisler Industries denester, which singulates and reorients each pail before sending them to the production line.
A conveyor moves pails into the filling area. The system also automates dunnage tray removal and pallet stacking, further reducing manual tasks.
Quick System Summary
- Industry: Industrial Coatings
- Product: 5-Gallon Steel Pails (Open-Head Nested and Tight head)
- Robot: FANUC M-410iB/140H Depalletizing Robot
- Throughput: 5 pails per minute
- Special Equipment: Heisler Industries Denester, Ambaflex Conveyor
- Footprint: Compact layout designed to serve two pail types in one space
This system proves that with the right tooling and smart layout, you can automate two completely different container types in the same space—without sacrificing throughput.
Motion Controls Robotics designed this robot system for a company in the building materials industry.
Depalletizing Steel Pails – System Videos
Watch our system video to see the robot in action and then go to Sequence of Operations below to read the full explanation.
Video of the newest system depalletizing empty steel pails.
A related system case packing and palletizing filled pails and buckets
Sequence of Operation - Depalletizing Steel Pails
The system was designed for fully automated depalletizing with minimal operator intervention and flexibility for two pail formats. Here's how the process works:
- The operator loads up to five full pallets of a single pail type, open head nested or tight head, onto the infeed conveyor.
- Pallets are aligned and positioned automatically using conveyor motion and sensor feedback.
- The operator selects the pail type and batch quantity at the HMI. The system selects the appropriate robot program and activates the correct gripper functions.
- For tight head pails, the robot uses a vacuum plenum-style gripper to pick two pails at a time and place them on the tight head pail conveyor for direct transfer.
- For open head nested pails, the robot lifts stacks of five pails. These are placed onto a Heisler de-nester infeed conveyor.
- The denester lays down the stack, singulates the pails, and reorients them upright for transport on the downstream conveyor.
- All pails travel via conveyor to the filling area.
- Throughout the process, the robot also removes corrugated top and bottom trays (dunnage). Empty pallets are automatically stacked for forklift pickup.
- Once the batch is complete, the operator resets the HMI and either continues with the same pail type or loads new product for the next run. The system tracks remaining pails and resumes without manual recalibration.
Robot Selection
To optimize performance of depalletizing steel pails and meet the customer’s requirements, we selected the FANUC M-410 robot for this solution:
- M410iB/140H: This is the robot known for palletizing and it works just as well to depalletize, ensuring efficient and precise depalletizing operations for both pail types.
You can explore the detailed specifications and download additional information about these FANUC robot models below.
Models |
Payload |
Reach |
Download Spec Sheet |
| Floor Mounted | |||
| M410iB/140H | 140 kg | 2850 mm | M-410iB-140H.pdf |
✓ Safety Features
Motion Controls Robotics follows the ANSI R15.06 Safety Standard designed to ensure employees and robots work safely together. We take full advantage of new safety technologies and innovations as they become available.
Other Safety Features
We design our systems with comprehensive safety measures to ensure a secure operating environment. These include standard features such as safety doors, fencing, sensors, light curtains, and emergency stop (e-stop) buttons. These safeguards are implemented to protect personnel while maintaining efficient and reliable system performance.
Customer Results
By combining high-speed robotic handling, a smart dual-path conveyor layout, and compact footprint design, this system delivers flexible, space-saving automation tailored to the customer’s production environment. It’s an example of how smart depalletizing can support high-mix manufacturing without compromise.
#mcricanhelp to bring space-saving automation to your container handling process.
Benefits Delivered by Robotic Depalletizing Steel Pails
- Space Efficiency: One cell handles both pail types, eliminating the need for separate depalletizing areas.
- Increased Throughput: Consistent 5-pail-per-minute rate with continuous accumulation for downstream filling.
- Reduced Labor: Automated pail, tray, and pallet handling reduces operator involvement and improves safety.
- Flexibility: Tooling and logic adjust automatically to accommodate pail type changes via the HMI interface.
- Seamless Integration: The system connects with an existing filling operation 200 feet away using overhead conveyor routing.
