Automatic Bundle Stacking

Precision Servo Driven Bundle Stacking For Plastic Container Handling

Automatic Bundle Stacking for plastic container handling

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Dyco has a full line of standard Rotary and Linear Bundle Stackers for plastic container bundle handling.  Additional options such as slip sheet insertion, dual stackers, cart Indexing, gantry loading, hybrid bulk palletizing, etc. provide solutions for multiple applications.

Why Choose Dyco

  • We utilize servo technology for precision bundle pick-up and placement
  • Dyco offers the widest range of automated solutions for bundle stacking
  • With Dyco’s leadership in bundle handling combined with our pallet handling experience we can offer unique integrated solutions



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Cart Indexing

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Add the Cart Indexing Option to your rotary stacker for added accumulation.  The cart indexes as each stack is complete, so you can stack up to three bundle stacks.  This provides additional time for an operator to perform other tasks and also reduces transportation time to your warehouse or truck loading.

Why Choose Dyco

  • Carts "lock" into position for stacking and can then be removed for transport
  • Precision Servo Driven motion control and integrate cart indexing make the system work
  • System can be added to an existing Dyco Rotary Stacker palletizing system


<alt= integrated 3 position cart palletizing systems

Integrated 3-position cart

Stacking in second position

Stacking in second position


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Rotary Stacker Palletizing System

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Take advantage of complete automation by having your bundles stacked with our Rotary Stacker Palletizing System.  The stacker picks up bundles of bagged bottles and stacks them for transport to the warehouse or loading into a truck.   Stackers are available as an integrated system with a Dyco auto bagger or as a stand alone unit added to an existing bagger.

Why Choose Dyco

  • Systems have a robust control system with touch screen operator control to vary stack heights for different bottles
  • Precision servo driven motion, far superior to other AC motor driven stackers with pressure activated stops that damage bottles


rotary stacker palletizing system

Rotary Stacker Palletizing System stacking dairy gallon bundles

Rotary Stacker with slip sheet insertion

Rotary Stacker Palletizing System placing slip sheets between layers

Rotary Stacker sorting bundles

Rotary Stacker Palletizing System sorting bundles


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Slip Sheet Inserting Palletizing System

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The ability to utilize slip sheets between your bundles is available with our slip sheet insertion option.  Further, a dual stacking system can be added on the end of an automatic bagger to palletize multiple container bundles.  We have provided these systems in both single and double stack configurations.

Why Choose Dyco

  • Dyco has over 30 years of bundle handling experience, giving us a unique understanding of bundle handling and custom stacking and destacking solutions
  • We have applied robotics safety standards to more complex stacking applications
  • Dyco offers single stack and double stack configuration to cut down on transport time to storage area


Dual stacking palletizing system stacking dairy gallons and tall quarts

Dual stacking palletizing system stacking dairy gallons and tall quarts

Integrated safety light curtain

Integrated safety light curtain

Five auto baggers and dual stackings systems

Five auto baggers and dual stacking systems


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Robotic Bagged Bottle Palletizing

Overview of Robotic Cell

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Contact Dyco for access to full length video.

The Dyco Robotic Bagged Bottle Palletizer was developed to stack bags of empty bottles produced by a Dyco Autobagger to prepare for shipment or storage. Unlike the Rotary Stacker system, this robotic machine can palletize multiple bundles per layer, maximizing pallet capacity. The system can handle multiple lines simultaneously, even with different products running.  Pallets can be fed using one of Dyco’s Pallet Dispensers, or picked and placed from a bin using Dyco designed end of arm tooling.  Bundles are then stacked, with slip sheets between them for stability, until a pre-set count is reached.  Once the stack is complete, a top frame is added before being discharged into a banding or wrapping station.

Blowmolding companies would benefit from a system like this for preparing containers for shipment to fillers or storage in warehouses for later usage.  The KUKA™ Robotics industrial arm can handle any bottle size and the high versatility of robotics means it can adapt to ever changing products, even ones that haven’t even been developed yet!

Why Choose Dyco

  • Reduces work place injuries from repetitive motion injuries due to manual palletizing
  • Easy to use control panel means your operators do not have to learn specialized robotics code for product changeovers and emergency stop resets
  • Capable of handling multiple bottle sizes and conveyor lines at once
  • Robotic head is designed to handle bottles, slip sheets, top covers, and pallets without changing tooling


Cloe Up of End of Arm Tooling

Cloe Up of End of Arm Tooling

View from pallet discharge side

View from pallet discharge side


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