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Robotic Depalletizing and Repalletizing System for Plastic Pails with Inline Labeling

This robotic depalletizing and repalletizing system automates the movement of plastic pails through an inline labeling operation while maintaining continuous pallet-in to pallet-out flow. A FANUC M-410iB/315 handles depalletizing and repalletizing, while a secondary M-20iB/25 manages tier sheet placement to protect throughput.

Designed to run at 10 pails per minute, the cell reduces work-in-process, eliminates off-line handling, and delivers consistent, streamlined pail flow from inbound pallet to finished unit load.

Plastic Pail Depalletizing

Customer Results

  • Continuous flow: Pails Depalletized → Inline Labeling (or other process) → Pails Repalletized
  • Throughput: consistent 10 pails per minute for a variety of SKUs
  • Less WIP: reduces staging and manual handoffs
  • Reducing labor complexity: Removes off-line/third-party steps and labor constraints
Throughput
10 pails / min
Primary Robot
FANUC M-410iB/315
Secondary Robot
FANUC M-20iB/25
Inline Operation
Labeling (NITA)

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Customer’s Challenges

The customer needed to automate a common pain point: moving plastic pails from inbound pallets, through an inline labeling step, and back onto pallets. They had a lot of WIP and were waiting on manual processing opportunities.

  • Reduce work-in-process (WIP) between depalletizing and labeling
  • Eliminate manual or off-line handling steps that add cost and variability
  • Support multiple pail sizes/SKUs without complicated changeovers
  • Maintain steady throughput and predictable pallet-out results
What mattered most
A single cell that keeps pails moving by depalletize, labeling, repalletize. All to reduce staging, rework, and operator touchpoints.

System Description

The cell depalletizes incoming plastic pails, feeds an inline labeling operation, then repalletizes finished pails into unit loads. The design includes controlled accumulation and a simple reject path so labeling issues can be handled without stopping overall flow.

Quick System Summary
Industry Consumer Goods & Chemicals 
Product Plastic pails (multiple sizes/SKUs)
Robots FANUC M-410iB/315 + FANUC M-20iB/25
Throughput 10 pails per minute
Special Equipment Inline labeler (NITA) + print/apply
Footprint See layout drawing below. Designed for pallet-in to pallet-out flow with compact conveyor routing.
Cell Footprint / Layout Drawing
Plastic Pail Depalletizing
Reduced WIP
Continuous flow reduces staging between depalletizing and labeling.
Inline processing
Labeling stays in the flow.
Simple exceptions
Operator-activated reject handles issues without stopping production.

Sequence of Operations

A step-by-step view of how the cell runs from pallet in to pallet out.

Step Operation
1 Add empty pallet: an empty pallet is added to have a pallet availabile for repalletizing.
2 Full pallets: fork truck loads full pallets and any stretch wrap is removed.
3 Depalletize: the primary robot uses vacuum tooling to pick multiple pails per cycle and place them onto the infeed conveyor.
4 Feed inline labeling: pails transfer into the inline labeling operation. Labeling is done by a Nita Labeler.
5 Discharge & accumulate: labeled pails return to the cell and queue in controlled groups for consistent robot pickup.
6 Reject when needed: the operator can reject pails and they are diverted to a reject conveyor without stopping overall flow.
7 Repalletize: the primary robot builds unit loads from labeled pails. Handle orientation is not required.
8 Tier sheet placement: the secondary robot places tier sheets during pallet build to keep the main robot focused on pail throughput.
9 Stretch wrap: completed unit loads transfer to the Wulftec stretch wrapper and exits automatically when complete.
10 Pallet out: wrapped pallets are ready for fork truck removal.
Sequence Visual
Two robots work in coordinated motion to maintain continuous pail flow. The M-410iB/315 performs the core depalletizing and repalletizing tasks, while the M-20iB/25 supports pallet build with tier sheet placement.
Plastic Pail Depalletizing

System Videos

The video on the left shows the system in action. The video on the right is an example of other pail handling we have designed.

Video 1: Depalletizing → Label → Repalletize
Video 2: Case Pack and Palletize Pails

Robot Information

FANUC M-410iB/315
Primary Robot: FANUC M-410iB/315
Handles the pail flow with multi-pick depalletizing to the label infeed, then repalletizing labeled pails into complete unit loads.
FANUC M-20iB/25
Secondary Robot: FANUC M-20iB/25
Dedicated to tier sheet placement during pallet build so the primary robot stays focused on pail throughput.
Cell highlights
  • Multi-pick vacuum tooling for plastic pails
  • Consistent pickup and palletize rate
  • Operator-activated reject path for exceptions
  • Stretch wrap discharge for finished pallets

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. Safety is addressed through guarding, controlled access, and clearly defined operator interaction points.

Perimeter guarding
Fixed guarding with interlocked access doors around robot work zones.
Safety sensing
Light curtains / safety devices at pallet entry/exit to support safe material flow.
Defined operator stations
Reject pushbutton and service access points are clearly identified.
Clear status indication
Stack light / HMI status supports quick understanding of run, stop, and fault conditions.

Customer Results

The system delivered an end-to-end cell that reduces WIP, simplifies handling, and creates consistent pallet-in to pallet-out flow around an inline labeling operation.

Benefits Delivered
Reduced WIP Continuous flow reduces staging between depalletizing, labeling, and repalletizing.
Eliminates off-line processing Labeling stays in the cell’s flow, reducing manual or third-party handling steps.
Consistent throughput Designed for 10 pails per minute across multiple SKUs.
Flexible for pail sizes Tooling and setup support different pail sizes/SKUs without adding steps.
Simple exception handling Operator-activated reject diverts non-conforming pails without stopping the cell.
Cleaner pallet build Tier sheet robot offloads repetitive sheet placement so the main robot stays focused on pail handling.
Looking for a similar cell?
If you’re moving pails or other products through an inline step (labeling or otherwise) and want consistent pallet-in to pallet-out flow with less WIP, we can help you evaluate the right layout and throughput strategy.
Contact Us to Start Talking about Your System

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