Full layer palletising

A high production capacity? Our solution, in which a robot palletiser places a full layer on the pallet at once, enables fast processing.

First, the products are formed into a full layer according to a predetermined pattern. Subsequently, transit to the pick position takes place. We use our self-written Trapo Pallet Stacking Design software to design the patterns and the stacking method on the pallet (which pattern on which layer).

Forming the products into a full layer can be realized in a conventional way or by using a formation robot.



Conventional layer formation

Conventional formation

If it concerns the production of products with exactly the same width, length and height for a longer period of time, the layers can be composed according to a fixed pattern. By using a number of standard components – the conventional way – we can realize the formation of the layers according to this fixed pattern.

Formation robot

Are there many products with different sizes that require a high degree of flexibility and fast switching? Then the robot palletiser in combination with a formation robot offers the solution. Depending on the products to be processed and the variation of the associated dimensions, there are several patterns for the composition of the layers. A formation robot can quickly switch between these different patterns.


Trapo has recently delivered two installations of which full layer palletising is a part. In project 1, the layers are prepared in a conventional way; a formation robot was used in project 2.

Project 1

In this project (see photo above), the same product or packaging is processed for a longer period of time. A conventional way to form the layers according to one fixed pattern was a suitable solution.


dimensions min. 450 x 300 x 200 mm
max. 600 x 400 x 200 mm
weight max. 24 kg/piece
capacity 19 products/minute
packaging materials cardboard/foil
pallet dimensions 1200 x 800 en 1200 x 1000 mm
slip sheets yes
layer formation conventionally

Project 2

In this project, complete pallet loads are called from a mini load system. There are several products with different dimensions and multiple pallet dimensions. A quick switch between the available patterns for forming the layers is required. Forming the layers in a conventional way is not possible in this situation. A formation robot provided the solution: with minimal interval, it is possible to switch to the processing of another product and to palletise on another pallet.

The robot palletiser in combination with a formation robot offers a high degree of flexibility and enables processing of larger numbers of products.

Depending on the production volume, several production lines can be connected to 1 robot palletiser.

In this project, it was decided to provide the pallet with foil (wrapping) during palletising to ensure the stability of the load.


dimensions min. 300x400
max. 400x600
weight max. 30 kg
capacity 1400 products/hour
packaging materials cardboard
pallet dimensions 1200 x 800 en 1200 x 1000 mm
slip sheets yes
layer formation formation robot