October is Safe Work Month, a perfect time to reflect on how automation can make your factory safer and more productive. Palletizing might be the last step in production, but it’s one of the toughest on your team.

Stacking boxes, bending, lifting, twisting — hour after hour. Injuries from repetitive strain and overexertion are among the most common on the factory floor, and they cost time, money, and valuable talent.

That’s where automation earns its keep — but only if it can work safely alongside people.

The Hidden Cost of Manual Palletizing

A single repetitive motion might not seem like much, but multiplied over thousands of cycles a week, it becomes a serious risk.

• Musculoskeletal injuries from lifting and twisting
• Fatigue and strain from repetitive movement
• Accidents from overstacked pallets or unstable loads

These risks increase as the workforce ages and as factories face labor shortages that force fewer workers to do more. This leads to unpredictable downtime, higher injury-related costs, and rising turnover.

From hazard to harmony: Designing PAL Ready for safe collaboration

PAL Ready was designed for the real world, one where humans and robots share the same workspace. Every detail supports safe, smooth interaction, without cages or complex barriers.

Here’s how it makes human-robot collaboration worry-free:

1. Built on collaborative robotics

PAL Ready uses a collaborative robot (cobot) designed to operate safely near people.

• Force and speed limits keep movement within safe parameters.
• Integrated safety sensors detect contact or abnormal resistance, stopping motion instantly.
• Rounded edges and lightweight design reduce impact risks.

It’s automation that works with your people.

2. Compact and contained

Safety starts with simplicity. PAL Ready has a compact footprint and keeps all components within a clearly defined zone. Operators can easily move around it without crossing into dangerous areas or tripping hazards.

The result is a clean, organized workspace that feels safe and stays safe.

3. Smart controls, predictable behavior

Every PAL Ready comes pre-programmed and pre-tested. That means no surprises in motion paths, speeds, or interactions.
Operators can confidently restart, pause, or adjust the system using an intuitive interface, with built-in safety stops and clear visual indicators.

No complicated coding. No unsafe improvisations.

4. Compliance that goes beyond checkboxes

PAL Ready meets international safety standards (ISO/TS 15066 for collaborative operation).

Paired with an on-site risk assessment, each system is fully assembled and ready to meet your specific safety standards, so you know it’s safe from day one.

Real results: Glenhaven Foods

At Glenhaven Foods, operators were previously tasked with stacking heavy boxes by hand. After implementing Lean Palletizing, the company saw:

• Reduced ergonomic strain for all operators
• Consistent palletizing without downtime
• ROI in just 13 months, thanks to labor savings and higher throughput

  

“It’s a very quick, fast, simple solution, and it’s one that can be rolled out at pace across multiple lines within a factory.”
— Ken Maguire, Managing Director, Glenhaven Foods

Lean Palletizing allowed employees to focus on higher-value tasks while the cobot safely handled repetitive, physically demanding work.

A safer path to productivity

Automation isn’t just about output; it’s about keeping people safe while keeping production steady. PAL Ready replaces high-risk manual palletizing with a reliable cobot system, allowing operators to focus on higher-value, lower-risk work.

When safety and productivity align, everybody wins.

Visualize PAL Ready in your space

With the Robotiq Palletizing Fit Tool, you can:

✅ Validate your application in minutes
✅ Generate a custom 3D simulation of your palletizing cell
✅ Calculate ROI and payback period with your real data
✅ Get a downloadable report to share with your team

Start fast. Scale with confidence. 
Fill out the Palletizing Fit Tool today and see if Lean Palletizing is right for your operation.