Today, the manufacturing landscape is more complex than ever. Companies are under pressure to meet rising demands, maintain quality, and control costs. Manual labeling and palletizing processes are time-consuming and prone to errors. While these tasks may seem simple, efficient labeling and palletizing processes are crucial in ensuring the supply chain operates like a well-oiled machine.

Automation in these areas is no longer a luxury; it's quickly becoming necessary. Robots can handle these tasks, performing them with higher accuracy, speed, and efficiency. Whether you're a small-scale manufacturer or a global enterprise, automation in labeling and palletizing could be the competitive edge your supply chain needs.

This article covers: 

• The types of robots suited for these tasks
• The benefits of automating these processes
• Financial considerations involved

Understanding these topics enables manufacturers to make informed decisions on implementing automation in labeling and palletizing to streamline their manufacturing operations.

What is automated labeling? 

Automated labeling refers to using robotic systems to apply labels to products, packages, or containers. 

Instead of human workers placing each label manually, a robot handles this task. Automation isn’t just about speed; it's also about achieving a level of accuracy and consistency that manual methods can't easily match.

Labels carry critical information, from ingredients and usage instructions to barcodes for inventory management. Labeling mistakes can result in:

• Recalls
• Fines
• Loss of consumer trust
• Failure of downstream processes 

Therefore, automated labeling is not just an operational upgrade; it's a strategic move to enhance product quality and supply chain efficiency.

Benefits of automating labeling processes

Enhanced labeling accuracy and consistency

One of the primary advantages of automated labeling is the improvement in accuracy and consistency. Robots are less likely to make mistakes than manual operators. In an environment where a single labeling error can lead to numerous costly, negative outcomes, the value of precision can’t be understated.

Adaptability to different product sizes and shapes

Manufacturing lines often handle various products that come in different shapes and sizes. With manual labeling, adjusting to these variations can be a slow and error-prone process. Robots, on the other hand, can be programmed to adapt to different product dimensions swiftly. This flexibility makes it easier to manage diverse product lines without compromising labeling accuracy.

Increased speed of labeling processes

Speed is of the essence in any production setting. The faster you can label, the quicker products move through the supply chain. Automated labeling systems significantly increase the speed of the labeling process. Not only does this mean more products get labeled in less time, but it also frees human workers to focus on tasks requiring more complex decision-making and skills.

Enhanced accuracy, adaptability, and speed can contribute to a more robust and resilient supply chain, setting the stage for long-term success.

The top 3 robots for labeling

Articulated robots

Articulated robots are incredibly versatile and can move in multiple directions. With specialized end effectors, they can handle complex labeling tasks, including applying labels to irregular shapes or hard-to-reach areas. These robots are valuable in manufacturing settings where products have varied geometries.

However, the complexity and range of motion that make six-axis robots versatile also make them more challenging to program and one of the more costly options. Additionally, their sophisticated mechanics might lead to higher maintenance costs over time.

SCARA robots for high-speed precision

SCARA robots excel in high-speed, high-precision tasks. They are well-suited for labeling tasks requiring rapid and precise label placement, such as small electronics manufacturing or pharmaceutical production.

However, SCARA robots are generally limited to horizontal movements, which may make them less adaptable to products that require labeling on multiple or irregular surfaces. Their specialized nature may also make them less versatile for many other tasks in a production line.

Collaborative robots (cobots) for adaptive labeling in mixed production lines

Cobots are designed to work alongside humans safely and are relatively easy to program. Their adaptability makes them ideal for mixed production lines where the types of products being labeled can change frequently.

Generally, however, cobots have lower speed and payload capacities compared to articulated robots. Cobots might not be the most efficient option if your labeling needs to include high-volume production with heavy items.

Choosing the correct type of robot for your labeling needs involves weighing these strengths and weaknesses against the specific requirements of your manufacturing operation. By matching the robot's capabilities to the complexities of your labeling tasks, you can optimize efficiency and accuracy.

Palletizing robots: Streamlining end-of-line operations

Once products are manufactured and labeled, the next step in the supply chain is palletizing. This process involves stacking products onto a pallet in an organized manner and preparing them for shipping or storage.

Advantages of automating palletizing processes

Efficient use of warehouse space through optimized stacking patterns

One of the most immediate benefits of robotic palletizing is the ability to optimize stacking patterns. Robots can be programmed to stack products to maximize the use of available space, both on each pallet and within a storage or shipping container. This efficiency is crucial for reducing storage costs and optimizing limited warehouse space.

Reduction in manual labor and associated injuries

Manual palletizing is often a strenuous and repetitive task, posing risks of workplace injuries like strains or back problems. By automating this process, you can significantly reduce manual labor and the associated risks of injury. Automation enhances worker safety and can lower healthcare and workers' compensation costs for your business.

Scalability to handle varying product loads and sizes

Robotic palletizing systems can be designed to handle a wide range of product sizes and weights, making them adaptable to different manufacturing needs. Whether you're stacking small boxes or heavy industrial equipment, robots can be programmed to handle the task efficiently. 

From optimizing warehouse space and improving worker safety to offering scalability and flexibility, robotic palletizing is a robust solution for modernizing your end-of-line operations.

Types of robots suited for palletizing

Articulated robots with high payload capacities

Articulated robots are highly versatile and can handle complex stacking patterns with ease. Their high payload capacities make them ideal for stacking heavier items. Their multi-axis flexibility allows them to pick and place products at various angles, making them well-suited for complex palletizing needs.

However, these robots are often larger and require more floor space. Given their complexity and range of motion, they can also be more expensive to purchase and maintain.

Gantry robots for larger area operations

Gantry robots are excellent for operations that require a large working area. They can move along multiple axes and are particularly useful for handling bulky or awkwardly shaped items. Gantry robots can also be customized considerably, allowing for a high degree of specialization based on your needs.

It’s important to understand, however, that the size and structure of gantry robots often mean they require a significant amount of overhead space. This can be a drawback if your facility has height restrictions. They are also generally slower than other types of robots, making them less suitable for high-speed operations.

Cobots for smaller-scale or mixed palletizing needs

Cobots are generally smaller, easier to program, and can quickly adapt to different tasks, making them ideal for smaller-scale logistics operations or facilities with mixed palletizing needs.

Similar to their application in labeling, however, cobots generally have lower payload capacities and may not be the best fit for heavy or high-volume palletizing tasks. Their slower speeds might also be a limitation in high-throughput environments.

The key to effective automation in palletizing is to match the type of robot with your specific operational needs. Whether you're looking for high payload capacities, flexibility, or a smaller footprint, there's likely a robotic solution that fits your requirements.

Costs and financial considerations for labeling and palletizing robots

Automation offers a range of benefits, but it comes with initial costs that manufacturers must carefully consider. The upfront investment in automated systems varies depending on:

• The type of robot
• Required peripherals
• Customization 
• Training
• Safety systems

Generally, more complex systems like articulated robots will be on the higher end of the cost spectrum, while simpler systems like cobots may be more budget-friendly. Roughly, labeling robot systems can range between $40,000 to $100,000+. Palletizing robots can range from $50,000 to well over $200,000 for large-scale systems.

In a competitive manufacturing landscape, leveraging automation in labeling and palletizing processes can provide a significant edge. The benefits are compelling, from achieving higher accuracy and efficiency to enhancing worker safety and scalability. While the initial investment and ongoing costs are important considerations, the long-term productivity and supply chain efficiency gains often justify the expenditure.

What’s next?

You may be ready to take the next step toward automating your labeling and palletizing processes, but where do you start?

The HowToRobot platform connects buyers of automation with a variety of suppliers in a streamlined, easy-to-use environment. 

Post your project on HowToRobot today for free, and begin receiving offers from vetted, relevant automation vendors from our supplier network.