Manufacturers today face increasing pressure to do more with less — fewer workers, shorter production runs, tighter packaging requirements, and nonstop SKU churn. Amid that complexity, one task remains central to how products leave the factory: palletizing. 

But while palletizing has long been a candidate for automation, adoption remains surprisingly low. As of 2025, only 29% of warehouses worldwide had implemented any form of automation, and fewer still had automated palletizing in place. For many facilities, this final stage of production remains a manual, labor-intensive bottleneck.

That’s changing. A new generation of intelligent, no-code palletizing systems — led by solutions like MujinOS — is transforming end-of-line operations. These systems combine industrial reliability with fast deployment, dynamic adaptability, and a level of ease that empowers operators without programming expertise. 

For manufacturers running high-throughput lines or managing high SKU volume, the business case is clear: intelligent palletizing isn’t just automation — it’s a strategic advantage. 

Mechanical Palletizers: Fast, but Frozen in Time

High-speed mechanical palletizers have been around for decades. In the right environment, they can move 50+ cases per minute. But they were built for long, homogeneous runs — not the modern reality of shorter runs, faster changeovers, and more diverse packaging. 

Traditional Robotic Systems: Flexible, but High-Maintenance

Robotic palletizers built with PLC + vision + robot combinations offer more flexibility than mechanical systems. But they come with major downsides: 

Even with vision systems and basic pattern libraries, these systems are brittle. Add a new case size, remove a slip sheet, or adjust throughput targets — and you’re back to reprogramming. 

Even single-SKU palletizing isn’t as simple as it looks. Manufacturers today face challenges such as: 

The result? Many manufacturers have stuck with manual labor, even when they know the cost in efficiency, safety, and scalability is high. 

No Reprogramming for SKU Changeovers 

Changeovers are no longer a project. With MujinOS, operators can switch SKUs or pallet patterns in seconds, without robot code, downtime, or engineering support. The system supports teachless, no-code configuration for SKU onboarding — aligning palletizing flexibility with the rest of the factory. 

This means faster adaptation to new products, reduced changeover costs, and more uptime across all shifts. 

Opportunistic Multi-Picking for Maximum Throughput

Instead of relying on preprogrammed pick sequences, MujinOS continuously analyzes incoming product flow and dynamically determines when and how to pick multiple cases. It executes multi-pick, multi-place (MPMP) cycles based on real-time conditions — maintaining high throughput even as inputs shift. 

Typical robotic systems plateau at 6–8 CPM. With opportunistic multi-picking, Mujin-controlled systems consistently hit 12–15 CPM, even with variable packaging.

On-the-Fly Pallet Pattern Creation 

Operators can create and validate new pallet patterns in under a minute using Mujin’s Pallet Builder — no CAD software, no engineering team, and no trial-and-error required. Just select the case, define the pallet constraints, preview the auto-generated layout, and save. It’s as simple as creating a recipe — and just as fast.

Flexible Pack Formation Profiles 

Mujin allows users to visually configure box sizes, placement rules, spacing, and offsets through its WebUI. These pack formation profiles support a wide variety of pallet patterns and packaging types — all without coding. This is critical for operations with mixed packaging, varying carton strengths, or regulatory shipping requirements across regions. 

As demand grows, it’s important to separate the systems that check a box from those that truly deliver long-term value. Whether you’re automating a single line or building a factory of the future, look for these capabilities: 

Rapid, Hands-Free Changeover 

Operator Simplicity 

Digital Twin and Simulation 

Multi-Pick Optimization 

Flexible Pack Profiles 

Infrastructure Compatibility 

Resilient, Reliable Performance 

Frozen Food Manufacturer 

With over 100 SKUs running through a shared palletizing cell, this operation needed flexibility, safety, and remote visibility. MujinOS delivered: 

Global CPG Company 

Faced with a range of household products and constant packaging changes, this customer deployed Mujin-controlled palletizers across several plants:

While most industrial palletizers aim for high-speed, high-volume environments, cobot palletizing offers a compelling alternative for small to mid-sized operations. 

Key advantages: 

When paired with intelligent control software like MujinOS, cobots can offer flexible, operator-friendly automation without major infrastructure changes. 

Palletizing is no longer just a necessary step — it’s a performance lever. The right system reduces labor dependency, increases throughput, enhances safety, and provides real-time control and insight. 

With solutions like MujinOS, manufacturers can: 

By combining industrial throughput with intelligent automation, Mujin transforms palletizing from a fixed endpoint into a dynamic platform for growth. Whether you’re a systems integrator or an end user, now is the time to rethink what’s possible at the end of your line.