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Use a separate, validated palletizing recipe for each case family unless the cases share the same placement geometry, handling behavior, and load requirements. A reliable setup records case and pallet measurements, designs the layer sequence before teaching positions, maps each case identity to the correct recipe, checks gripper and robot limits, and validates both the individual patterns and the changeover logic on the actual cell.
Pattern-generation software calculates positions; it does not automatically prove that a mixed or single-SKU load will remain stable. Treat layer order, orientation, overhang, sheet handling, and stack height as process decisions, then commission the robot under the installed controller’s safety procedures.
Why different case sizes normally need different recipes
A pallet pattern is a set of placement coordinates tied to a particular case footprint, orientation, layer arrangement, pallet footprint, and stack height. When any of those dimensions changes, the same coordinates can create excessive overhang, unused pallet space, collisions, unstable columns, or an orientation that violates labeling or opening requirements.
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Use one recipe only when the geometry is genuinely common
A shared recipe can be appropriate when products have the same length and width, the same permitted orientation, comparable weight and rigidity, identical label-orientation rules, and the same pallet and sheet arrangement. Confirm the smallest dimensional tolerance and the heaviest payload rather than assuming that nominally similar cartons are interchangeable.
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Create a case family when handling or stability changes
Separate families are warranted when cases differ in footprint, height, center of gravity, compression strength, surface friction, label direction, barcode visibility, or the way the gripper must contact them. A family can contain several SKUs only when the common recipe has been proven for every member.
1. Measure the cases, pallet and cell before teaching positions
Capture the values below for every case family. Record actual production ranges, not only catalog dimensions, and identify any feature that changes how a tool can pick or release a case.
| Input | What to record | Why it affects the pattern |
|---|---|---|
| Case geometry | Length, width, height, dimensional tolerances and crush-prone faces | Determines layer coordinates, clearances and allowable compression |
| Mass and center of gravity | Nominal and maximum weight; center-of-gravity offset when known | Sets payload, acceleration and release-stability requirements |
| Handling surface | Cardboard finish, film, dust, seams, voids and areas that cannot be contacted | Determines whether vacuum, clamp, fork or combination tooling is suitable |
| Orientation rules | Label, barcode, print, opening and product-facing direction | Restricts rotations that would otherwise improve pallet utilization |
| Pallet | Usable length and width, deck-board details, allowable overhang and maximum stack height | Defines the coordinate frame and the safe envelope |
| Load materials | Slip-sheet and top-sheet dimensions, thickness, placement and whether a sheet is used per layer | Changes layer height, friction and the robot sequence |
| Line behavior | Infeed spacing, case rate, SKU change frequency and pallet-change method | Determines recipe-change timing and achievable throughput |
Fuji Robotics identifies case geometry and weight, rigidity, rate and spacing, label orientation, SKU changes, pallet pattern, stack height, tooling, payload, reach and cell layout as application variables. Use that same broad checklist even when another robot brand is installed.
Separate dimensions from tolerances
Enter the nominal dimensions used by the pattern generator, then document the tolerance that the gripper and pallet must accommodate. If a carton bows, flaps open, or varies enough to alter contact, treat that behavior as a handling constraint rather than hiding it in a nominal measurement.
2. Decide the pallet geometry and layer sequence before programming
Do not begin by teaching points at the pendant and then attempt to infer the load plan. First approve a drawing or digital layout showing every case in every layer and the order in which layers are built.
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- Choose the orientation of cases in each layer. Decide which face points toward the pallet edge and whether alternating or interlocked layers are allowed by the case strength and product requirements.
- Define the relationship between layers. Specify whether successive layers repeat, rotate by 90 degrees, mirror, or use a different pattern. Mark the first and last layer explicitly.
- Set the edge and overhang policy. Keep the footprint inside the permitted pallet boundary unless the process owner has approved a measured overhang and the pallet and downstream equipment can accept it.
- Place sheets in the sequence. Identify whether a slip sheet is loaded before the first layer, between layers, or only at the top, and reserve a motion and confirmation for each sheet operation.
- Approve mixed-load order separately. For a mixed pallet, define which case family is placed first, how the center of gravity evolves, and what constitutes an acceptable finished load. The robot pattern function may generate positions without enforcing those stability rules.
The FANUC-focused application guide specifically warns that its built-in palletizing instruction does not provide stack-stability rules. Plan the sequence outside the robot program and confirm the final arrangement with the process owner, packaging engineer or responsible integrator.
Use a stable coordinate convention
Establish pallet origin, X and Y directions, Z height, approach direction and tool reference point before generating positions. Document whether dimensions are measured to the case outside surface, gripper centerline or tool reference frame. A consistent convention prevents a correct pattern from being shifted by a frame-definition error.
3. Structure each recipe so a technician can audit it
Give every case family a human-readable identifier and store the values that produced its positions. A recipe should be reproducible without relying on undocumented pendant edits.
| Recipe field | Example content | Audit question |
|---|---|---|
| Recipe ID and revision | CF-042, revision 03 | Can the controller and production record identify the exact version? |
| Case definition | Length, width, height, mass range and orientation code | Does the recipe match the case physically entering the cell? |
| Pallet definition | Usable footprint, origin, maximum height and overhang limit | Are all coordinates inside the approved pallet envelope? |
| Layer map | Positions, rotations, layer count and alternating-layer rules | Can an operator see the intended build without reverse-engineering points? |
| Material sequence | Slip-sheet, case, top-sheet and pallet-change actions | Are non-case motions included in the cycle? |
| Tool limits | Permitted mass, contact zone, vacuum or clamp conditions | Can the installed end effector safely pick every member of the family? |
| Selection key | SKU code, register value, digital-input code or host message | How does the robot know which recipe to load? |
| Validation record | Date, test cases, exceptions and approver | Is there evidence that this revision ran successfully on the actual cell? |
Use a naming scheme that makes a wrong selection obvious, such as CF042_400x300x250_REV03. Keep the dimensions in the engineering record even if the controller stores only a numeric recipe number.
4. Choose the platform-specific pattern method
There is no universal pendant workflow. The concepts are portable, but menu names, licenses, coordinate systems and program instructions depend on the installed robot, controller software and palletizing package.
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Kawasaki neoROSET workflow
Kawasaki Robotics describes a six-step palletizing function in its 2026 small-to-medium robot material: select the robot and material-handling setup, choose a layout, enter workpiece and pallet dimensions, generate palletizing positions, load the positions to the robot, and execute. The described function includes more than 100 built-in patterns and requires an additional optional license.
- Select the robot model, material-handling configuration and cell equipment.
- Choose the closest layout or pattern template for the approved layer drawing.
- Enter workpiece dimensions, pallet dimensions, layer information and any required orientation values.
- Generate the palletizing positions and inspect the resulting footprint, height and clearances.
- Transfer the generated positions to the controller using the documented neoROSET procedure.
- Execute a controlled dry run and then a loaded run under the cell’s commissioning process.
Kawasaki’s capacity figures are reference values, not guarantees. Actual performance varies with robot model, item shape and weight, transport conditions and surrounding equipment. Confirm the optional-license status and supported functions for the exact installed version.
Robotiq PE Series workflow
The PE Series instruction manual organizes configuration into separate SETTINGS, BOX, PALLET and PATTERN areas. Use the box area for case dimensions and handling values, the pallet area for pallet geometry and height limits, and the pattern area for editable positions and layer sequences. The manual’s screens and parameter names are product-specific; do not assume another robot or gripper exposes the same fields.
After editing a pattern, save the recipe under the approved case-family identifier, verify the active layer sequence, and test the loaded recipe with the actual tool. Keep a controller backup and a copy of the engineering record before changing production values.
FANUC R-30iB selection example
The FANUC application example describes teaching a separate pattern for each case family and selecting the pattern in TP program logic from case identity supplied through the cell’s own register, digital input or host interface. A typical arrangement is:
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- Receive and validate the case-family code.
- Map that code to one approved pattern and one layer sequence.
- Reject or hold an unknown code rather than defaulting silently to the previous recipe.
- Run the selected pick, place, layer-complete and pallet-complete logic.
- Record the active recipe with the production or traceability system.
This example comes from an application guide rather than a FANUC primary manual. Confirm instruction syntax, register behavior, option requirements and recovery procedures against the installed R-30iB documentation and software revision.
5. Verify the gripper, payload and robot envelope
A mathematically correct pattern fails if the tool cannot acquire the smallest case, hold the heaviest case or reach the highest layer without collision. Check the complete moving mass: case plus gripper, adapters, hoses, sensors and any carried sheet.
| Check | Acceptance question | Typical corrective action |
|---|---|---|
| Pickup contact | Does the tool contact a flat, strong and repeatable surface on every case? | Change pad placement, clamp width, fork support or the case family definition |
| Payload | Is the maximum case mass plus tool mass within the robot and wrist ratings at the required reach? | Reduce acceleration, select a higher-rated robot or redesign the tool |
| Reach and clearance | Can the robot approach and withdraw from every coordinate at the highest layer without singularity or interference? | Adjust pallet origin, approach vector, layer pattern or cell layout |
| Release behavior | Does the case settle without sliding, tipping or catching on an adjacent case? | Change release height and speed, add guidance or revise the layer arrangement |
| Surface variation | Do dust, film, seams or porous cardboard reduce vacuum or clamp reliability? | Use different tooling, add sensing or split the family by handling surface |
Fuji describes vacuum, clamp, fork, combination and custom tooling as application-specific choices. Throughput also depends on case size and weight, pick count, infeed spacing, travel, pallet pattern and height, tool design and overall line flow. Do not assume that two different case sizes can be picked together simply because the robot has enough nominal payload.
Understand multipick limits
The Robotiq PE Series manual states that cases picked together by its multipick feature must have the same dimensions and payload and must be picked and dropped side by side. That is a limitation of the documented implementation, not a universal rule for every robot, gripper or custom tool. For mixed dimensions, use single picks unless the installed system documentation and validation prove a different arrangement safe.
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Recipe selection should be an explicit state in the cell, not an operator assumption. The source of case identity may be a barcode reader, manufacturing-execution message, PLC register, digital-input code or an operator selection protected by authorization.
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- Acquire identity. Read the SKU or case-family code before the case reaches the pick point.
- Validate the code. Check that it exists, is enabled for the current pallet and has a completed validation record.
- Confirm the physical case. Use dimensions, barcode, vision or upstream controls as available to detect a mismatch between the code and the case.
- Load the recipe. Set the pattern, layer sequence, tool mode and sheet sequence as one atomic change.
- Interlock motion. Do not allow a pick until the recipe is acknowledged and the pallet state is compatible.
- Handle an unknown or late change. Stop or divert the case; never continue with the last active recipe by default.
- Commit the changeover. Record the new recipe ID and clear any partial-layer state according to the approved recovery procedure.
receive case_family_code
if code is not approved:
hold case and alarm operator
else if recipe_revision is not validated:
hold case and alarm maintenance
else:
load pattern and layer_sequence
acknowledge recipe
enable palletizing cycleThe pseudocode illustrates the control intent only. Implement the equivalent logic using the installed PLC, robot language and safety architecture, and define what happens after power loss, e-stop, pallet replacement or a manually removed case.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.7. Validate every recipe and then validate the changeover
Commissioning should progress from an unloaded motion check to representative production. Use the robot manufacturer’s documented safety and teach-mode procedures, the integrator’s risk assessment and the requirements of the applicable jurisdiction.
- Back up the cell. Save controller programs, pattern data, tool files, frames, PLC logic and the recipe register before testing.
- Dry-run each coordinate. Verify approach, pick, transfer, release and retreat with no case or at reduced speed as permitted by the commissioning procedure.
- Test representative extremes. Use the lightest and heaviest cases, smallest and largest dimensions, worst surface condition and highest planned layer.
- Check orientation. Confirm labels, barcodes, openings and product-facing sides on every relevant layer.
- Check clearances. Inspect pallet edges, neighboring cases, sheet dispensers, conveyors, guards, sensors and hoses.
- Complete a full pallet. Verify layer counting, sheet actions, pallet-full detection and pallet-change sequencing.
- Exercise recovery. Interrupt at pickup, transit, release, layer completion and pallet change; then follow the approved restart method.
- Run a mixed production sequence. Change among all case families and confirm that identity, recipe, layer state and traceability remain synchronized.
- Inspect the finished load. Measure overhang, lean, gaps, compression damage and stability after transport or the next downstream operation.
| Test stage | Evidence to record |
|---|---|
| Recipe load | Requested family, active recipe revision and controller acknowledgment |
| Pick | Successful acquisition, grip or vacuum confirmation and no case damage |
| Placement | Coordinate reached, release confirmed and adjacent-case clearance maintained |
| Layer completion | Correct count, orientation and sheet action |
| Pallet completion | Height, footprint, stability and pallet-change signal |
| Fault recovery | Safe stop, restart point, duplicate-placement prevention and operator message |
8. Compare candidate patterns using the whole cell
The pattern that fits the most cases on a pallet is not automatically the best production pattern. Compare each candidate against the following criteria before approving it.
| Criterion | Questions to answer |
|---|---|
| Footprint utilization | How much of the usable pallet area is filled, and is any overhang permitted? |
| Stability | Does the layer sequence resist sliding, tipping and column collapse for the actual case strength? |
| Orientation | Are labels, barcodes, openings and product faces presented correctly? |
| Tool compatibility | Can the gripper acquire and release every case without changing an unapproved setting? |
| Robot envelope | Are all positions reachable with approved payload, wrist limits and collision clearance? |
| Changeover | Can case identity reach the robot in time, and is an unknown code blocked? |
| Height and sheets | Does the finished stack stay below the permitted height with all sheets included? |
| Throughput | Does travel, pick count, infeed spacing and downstream flow support the required rate? |
For a mixed-case pallet, evaluate the entire build order rather than optimizing each layer independently. A pattern that saves one case per layer may increase travel, create a weak interface between layers or make the final pallet unstable.
9. Troubleshoot common failures
| Symptom | Likely cause | Action |
|---|---|---|
| Cases overhang the pallet | Wrong pallet dimensions, origin, orientation or recipe selected | Verify the active recipe ID and coordinate frame, then regenerate positions from measured pallet dimensions |
| Robot reaches a position but collides during approach | Tool center point, approach vector or neighboring-case clearance is wrong | Recalibrate the tool and frame; inspect approach and retreat paths at reduced commissioning speed |
| Vacuum or clamp loses the case | Surface variation, center-of-gravity shift, insufficient contact or excessive acceleration | Test the worst case, adjust contact or tooling and retest payload and acceleration limits |
| Correct cases receive the wrong pattern | Stale register, delayed host message, ambiguous code or fallback to the previous recipe | Add identity acknowledgment, timeout handling and an explicit unknown-code stop |
| Layers look correct but the pallet leans | Unstable build order, case compression, uneven pallet deck or unapproved mixed sequence | Review the complete stack with the process owner and change the layer sequence or pallet preparation |
| Multipick fails on mixed cases | Cases do not meet the implementation’s same-dimension and same-payload requirement | Use single picks or obtain documented approval for a different custom solution |
| Cycle time misses the target | Extra travel, low infeed spacing, excessive picks, slow tool response or downstream blockage | Measure the full cell cycle and optimize pattern, tool, infeed and flow together |
10. Maintain recipes as controlled production data
Store the approved pattern, dimensions, tool settings, selection code, revision, validation date and approver together. Back up controller and PLC data before edits, and require a change record whenever a case, pallet, tool, software version or layer sequence changes.
Revalidate after a robot software upgrade, tool modification, pallet change, new carton supplier, altered case weight, new sheet material or any change that affects reach, payload, friction or orientation. Keep a printed or electronic layer drawing at the cell so an operator can identify the intended build without opening the program.
Decision rule for a multi-size palletizing cell
Start with one recipe per case family. Share a recipe only after measurements show that the cases use the same placement geometry and handling limits. Select the recipe from a verified case-identity signal, keep stack-stability planning outside the coordinate generator, and approve the result only after full-pallet and changeover tests on the installed robot, tool and pallet.
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