Robotic Palletizing & Depalletizing

Dyco is your palletizing automation partner!

Robotic Box & Bag Palletizing

Click image to watch short video.
Contact Dyco for access to full length video.

Dyco’s Robotic Palletizing Systems have been integrated with proven, technically advanced KUKA robots, to provide you with increased flexibility to simultaneously palletize multiple lines with different product packages, while retaining the adaptability to program for future products and packages. Dyco’s Integrated Robotic Palletizing Systems provide the best incentive to eliminate the inherent inefficiency and repetitive lifting risks associated with manual palletizing operations.

Why Choose Dyco

  • Palletizing Robot is flexible for future use; pack patterns can be easily reconfigured
  • Ability to handle multiple production lines with different products simultaneously
  • Easy to use operator friendly touch screen controls



^Back to top^


Robotic Bulk Bottle Palletizing System - Two Row Picking

Palletizing System for alternating rows of one-gallon juice containers

Click image to watch short video.
Contact Dyco for access to full length video.

Dyco brings robotics to its proven Bulk Bottle Palletizing Systems for empty plastic containers. By applying robotic lifting and positioning of bottles, you gain production performance as well as greater flexibility when changing to or between different container sizes and configurations. Dyco’s Robotic Bulk Palletizing Systems are specifically designed for unstable plastic containers, and are fully automated from bottle infeed to pallet discharge, requiring only system monitoring and the replenishment of pallets, divider sheets and top-caps. The robotic palletizing arm is fitted with interchangeable, multipurpose clamp tooling that securely grasps and lifts bottles from the infeed conveyor and positions them onto the pallet. For added stability, rows can be placed in alternating directions Dyco’s unique, servo-driven Stabilizing Ring interfaces with bottle placement to provide row and tier support essential to stacking empty bottles. The Stabilizing Ring supports each row as it is positioned in the tier, and retains control until the next row is placed. It also provides a surrounding side wall for both the tier that is being formed and the finished tier underneath. When the tier is filled, the robot positions a corrugated slip-sheet, and the Stabilizing Ring rises to accept the next tier. Pallets are finished with a slip-sheet and top-cap, then released and transported to the finishing area for banding and stretch wrapping while an empty pallet automatically moves into loading position. The Robotic Bulk Palletizing System is managed by Dyco’s system PLC with its user friendly touch screen controls, and Dyco’s proprietary robot program which will accommodate changes to new containers without re-teaching or reprogramming the robot. 

Why Choose Dyco

  • Continuous bottle stabilizing as the pallet is being formed
  • Quick change over, and cost effective adaptation to bottle changes
  • End of arm tooling designs incorporating over 35 years of bottle handling experience


Robotic Palletizing System for alternating rows of one-gallon juice containers

Precision slipsheet placement, while the array below is fully captured in the stabilizing tower

Precision slipsheet placement, while the array below is fully captured in the stabilizing tower

Palletizing one-gallon oil containers into a fully stabilized array

Palletizing one-gallon oil containers into a fully stabilized array


If you like this you may also like:


^Back to top^


Robotic Bagged Bottle Palletizing

Overview of Robotic Cell

Click image to watch short video.
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


If you like this you may also like:


^Back to top^


Robotic Tray Palletizing

Click image to watch short video.
Contact Dyco for access to full length video.

The Dyco Robotic Tray Palletizer is designed for palletizing trays filled with oriented empty bottles. The system locates and picks up trays, stacks them onto a located pallet, places a top cap on the completed stack, and then discharges the palletized load through an integrated bander or stretch wrapper.  If desired, a thin layer of plastic film or a slip sheet can be placed between layers. 

Companies that manufacture or fill blowmolded plastic containers commonly use this solution to store and ship personal care, chemical, and other industrial type containers.  Completed pallets can be easily moved with a fork lift for storage in a warehouse or transport to an off site filling location.  Individual trays of the plastic bottles can be easily unloaded into a bottle descrambler feeding a filling line.

Why Choose Dyco

  • Eliminates manual labor and repetitive motion injuries associated with hand palletizing
  • Reduces packaging costs. Trays, pallets, and slip sheets are typically used multiple times
  • Trays of oriented bottles maximize storage space, reduce freight costs, and minimize bottle damage
  • A sheet of plastic film over all bottles minimizes contamination from cardboard dust


Robotic Tray Palletizer placing a sheet of plastic film over a layer of trays

KUKA™ Robotic Arm placing a tray


If you like this you may also like:


^Back to top^


Robotic Box Palletizing System

Click image to watch short video.
Contact Dyco for access to full length video.

With a Dyco Full Product Robotic Palletizing System you can increase your production capacity and reduce the labor required for manual palletizing.  Typical applications include end of line palletizing of finished goods in a filling plant or end of line palletizing empty bottles in reshipper boxes.  Another patented innovation by Dyco

Why Choose Dyco

  • Reduce the potential of injuries associated with manual palletizing
  • Multifunction end of arm tooling to pick-up different products and slipsheets
  • Easy to use touch screen, your operators don't need to know robot code


Robotic Palletizing Of Full Cases of Milk

Robotic palletizing of full cases of milk

Palletizing Open Top cases of empty bottles

Palletizing open top cases of empty bottles

Palletizing Tray Packs of Single Serve Milk Bottles

Palletizing tray packs of single serve milk bottles


If you like this you may also like:


^Back to top^


Robotic Nested Flap Box Palletizing - SingleStack

Robotic arm stacking boxes for palletizing

Click image to watch short video.
Contact Dyco for access to full length video.

With our Robotic Open Flap Box Palletizing System, you can now palletize boxes full of bottles for shipment.  This cell is capable of stacking boxes with major flaps folded in and minor flaps out.  Once complete, a half-high "cube" of boxes is ejected and ready for strapping and removal by a fork truck.  The machine is even capable of inverting the topmost boxes to create a flat, perfectly stackable end product for shipment or storage.

Blowmolders would benefit from this because of the labor intensity of manual box stacking.  This robot completely eliminates the repetitive motion, preventing workplace injuries.  Our systems can be adapted to fit any bottle or box size in any height or pallet configuration to best fit your needs.

Why Choose Dyco

  • Easy to use touch screen controls means less training and faster changeovers
  • Robotic systems allow for a versatile unit which can be adapted to new products or configurations
  • Multiple cells can be combined for faster pallet formation


Overview of Robotic Stacking Cell

Overview of Robotic Stacking Cell

Robot stacking boxes between flaps for stability

Robot stacking boxes between flaps for stability


If you like this you may also like:


^Back to top^


Robotic Bag Palletizing

Click image to watch short video.
Contact Dyco for access to full length video.

We have a Full Product Robotic Bag palletizing solution. Typical applications include end of line palletizing of bagged bulk solid products. Change products simply through an HMI. No robot training required to changeover products, recover from E-stops or reset the system. Dyco Inc technology enables tight nesting to reach maximum stack capacity.

Why Choose Dyco

  • Gentle product pick-up with custom designed end of arm tooling
  • System includes the ability to store multiple stack recipes to handle all your production requirements


Palletizing system placing 50 lb bags of insulation

Rake style end of arm tooling for gentle product handling


If you like this you may also like:


^Back to top^


Robotic Bulk Bottle Depalletizing

Robotic Bulk Bottle Depalletizer

Our Robotic Bulk Bottle Depalletizer allows for faster production rates compared to hand depalletizing.  Simply load pallets of bottles, remove the banding or wrapping, and the robot takes care of the rest.  Dyco designed end of arm tooling allows the robotic arm to handle slip sheets, top frames, and pallets in addition to bottles.  The robotic arm places the top frames and slip sheets onto a pallet as well as making a separate stack of empty pallets for reuse.  The bottle arrays are placed onto a Dyco Mat Top Conveyor system to be indexed into a single row Table Top Conveyor for downstream processes like cleaning and filling.

 Filling companies can increase production capacity and eliminate repetitive motion injuries through the use of a Dyco Robotic Bulk Bottle Palletizer.

Why Choose Dyco

  • Customized end of arm tooling to fit your bottle size
  • Easy to use operator control panel means your employees do not need to learn specialized coding
  • Can be programmed with multiple recipes for faster changeovers and adapt for future products
  • KUKA™ industrial robotic arm provides reliable, repeatable accuracy at a high rate of speed


Depalletizing Robot Head

Depalletizing Robot Head

Overview of Depalletizer Cell

Overview of Depalletizer Cell

View inside of PLC control cabinet

View inside of control cabinet


If you like this you may also like:


Contact Us | Privacy Policy | Site Map | Site Credits: Ecreativeworks