To keep shelves stocked efficiently and create an eye-catching shopping experience, you need well-organized, stable, and display-ready pallets. MCRI’s automated end cap palletizing system takes the hassle out of palletizing by automating the process for building quarter-pallets, half-pallets, and full pallet loads. With efficiency, speed, and full compliance with your retailer’s standards, you can streamline operations while ensuring your products are presented in a visually appealing, shelf-ready pallet.
Customer’s Challenge
Why the Customer Chose an Automated End Cap Palletizing System
The customer turned to Motion Controls Robotics in search of a more efficient and cost-effective way to assemble end cap-ready pallets. Their current process was too expensive and lacked the flexibility required to adapt to shifting product demands. Aware of the growing challenges tied to labor availability and reliability, they recognized the need to future-proof their operations. By implementing an automated end cap palletizing system, they aimed to enhance consistency, lower long-term costs, and gain greater control over their palletizing process.
MCRI’s Solution for Assembling End Cap Displays
To meet the customer’s needs, Motion Controls Robotics engineered a fully automated End Cap Pallet Display Assembly System designed for both performance and flexibility. To start, the system includes configurable single- and dual-level SKU lanes to accommodate a wide range of product types and volumes. In addition, a high-speed sortation loop ensures continuous product movement while feeding two palletizing cells for efficient layer building.
Furthermore, each cell features dual robots—one dedicated to palletizing and the other to dunnage handling—working together to eliminate downtime and maintain high throughput. Quick-change end-of-arm tooling enables the system to manage various case formats, including RSC, open-top display-ready cases, and plastic bins.
To improve operational visibility, the system is equipped with a real-time Impact IQ dashboard, offering operators step-by-step guidance and live SKU tracking. As a result, the customer gained a cost-effective and scalable solution that enhances consistency, reduces manual labor, and adapts easily to changing retail demands and future growth.
This system gives our customer the flexibility to adapt to changing demands while future-proofing our palletizing process with consistent, automated performance.
Testimonial by: Jim Skelding, VP of Sales and Marketing
Why the Customer Chose an Automated End Cap Palletizing 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.
Sequence of Operations
Assembling End Cap Ready Pallets
System Overview
Motion Controls Robotics’ fully automated End Cap Display Palletizing System is designed to handle cases and pallets from start to finish, ensuring accuracy, speed, and flexibility for high-mix SKU operations.
Inputting Cases into the System
MSRS: Operators manually place cases into the system.
ASRS: A robot depalletizes cases by layer, rows, or individual units.
The system includes banks of ten SKU lanes, arranged for optimal product flow. Lanes can be configured as single- or dual-level, offering flexibility to support expanded SKU storage.
Cases are loaded onto conveyors from staged pallets, and a real-time Impact IQ dashboard guides operators through each step with SKU-specific data. As cases progress, they are scanned for accuracy, and the system will automatically pause and correct any detected sequencing errors.
The Sortation Loop
Once in the system, cases travel along the sortation loop to their designated palletizing lanes. This loop feeds two case pick areas simultaneously, allowing one lane to build a current layer while the other prepares the next. Cases can repeat the loop until they are moved into the palletizing lane. This significantly boosts cycle time and prevents jams by maintaining a smooth product flow.
Robot Palletizing Cell – Unit Load Build
The system features two scalable pallet build cells. Operators configure each cell with the appropriate pallet size, slip sheets, tier sheets, or layer pads. Each cell contains:
- Two robots – one for palletizing, one for dunnage handling
- A pallet and layer pad magazine (holds up to 7 pallet sizes ranging from 20×24 to 40×48)
- Quick-change end-of-arm tooling
The palletizing robot can pick RSC cases, open-top display-ready cases, and plastic bins using fork tools or plenum vacuum tools. Both palletizing stations continuously build 1/4, 1/2, or full-size pallets.
Notably, palletizing continues during dunnage replenishment, eliminating downtime. Finished stacks then move to the finishing area.
Case Specifications
- Weight Range: 2 to 50 pounds
- Size Range: 9″ x 11″ to 20″ x 24″
- Throughput: 24 – 40 cases per minute
Finishing Area & Banding
In this manual area, operators apply required branding, signage, and dunnage. The load is then secured by an automatic bander with the ability to apply one or two bands per pallet. Additionally, it can apply cross-directional bands via a turntable, enhancing load stability.
Unitizer – Transport Pallet
As finished pallets enter the Unitizer, a dedicated robot builds transport-ready unit loads. Configurations include:
- Four (4) 1/4 pallets
- Two (2) 1/2 pallets
- A combination of 1/4 and 1/2 pallets
The unitized load moves into the stretch wrapper, which secures the pallet for transport. For additional protection, an optional poly top sheet shields against dust and moisture. The final step is automated labeling on up to four sides for clear identification and tracking, making the pallet ready for distribution.
FANUC Robot Selection for Automated End Cap Palletizing System
To optimize performance and meet the requirements of this automated end cap palletizing system, we selected three FANUC robots—each chosen for its strength, speed, and precision in high-throughput environments:
- The first palletizing cell uses a FANUC M-410iC/185 and M-410iB/140H
- The second palletizing cell uses two M-410iB/140H to handle heavier loads with the tray/open top handling tool
- The unitizer transport pallet system uses a FANUC M-410iC/500 to pick and place quarter- and half-pallets
You can explore the detailed specifications and download additional information about these FANUC robot models below.
Models |
Payload |
Reach |
Download Spec Sheet |
| Floor Mounted | |||
| M-410iC/185 | 185 kg | 3140 mm | M-410iC/185 |
| M-410iB/140H | 140 kg | 2850 mm | M-410iB/140H.pdf |
| M-410iC/500 | 500 kg | 3143 mm | M-410iC/500.pdf |
✓ Safety Features
Motion Controls Robotics follows the ISO 10218-1:2025—Robots And Robotic Devices 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 with Automated End Cap Palletizing System
By implementing Motion Controls Robotics’ automated end cap palletizing system, the customer achieved a streamlined, automated solution tailored to their evolving retail needs. The system reduced long-term operational costs, improved consistency in display builds, and delivered the flexibility to handle high-mix SKUs and seasonal changes. Most importantly, it positioned the company for future growth with a scalable, labor-conscious solution that increases throughput and maintains quality—no matter the product mix or production schedule.
Ultimately, the industry’s growing focus on automation to enhance both efficiency and safety is driving the widespread adoption of advanced palletizing solutions. If you are interested in exploring this type of automation for your facility, contact us using the button below.
