Complete robotic palletizing and automatic wrapping system | End-of-line automation by Dasstec
Client: Instant Ice | Food industry | Application: ice cubes
Dasstec has completed factory testing for a complete end-of-line automation system for automatic palletizing and wrapping of boxes and crates, integrating industrial robots, transport systems – conveyors, layer stabilization/alignment during palletizing, application of separator cartons, and labeling after wrapping.
The solution is designed for continuous operation in intensive industrial environments, in temperatures ranging from 2 to 40 degrees Celsius, with high requirements for productivity, pallet stability, and flexibility for multiple product types.
Solution architecture
The project includes a fully integrated line, from picking up the boxes to the final pallet wrapped and labeled:
✔️ Robotic palletizing with two ABB industrial robots, picking from five production streams and palletizing in four pallet positions.
✔️ Vacuum grippers for handling boxes and bags
✔️ Automatic pallet load stabilization system (elevator with centering devices on each layer)
✔️ Automatic pallet storage
✔️ Automatic application of cardboard separators at the base of the pallet
✔️ Pallet conveyors and heavy-duty transfer systems
✔️ Automatic wrapping with rotating arm (stationary pallet)
✔️ Automatic application of double-sided logistics labels
✔️ Full integration of safety and Ethercat PLC automation, made by Dasstec.
The system simultaneously serves multiple production flows with different products and packaging:
✅ Until 768 crates/hour per robot
✅ Until 256 pallets / 24 hours
✅ Over 184 tons/24 hours total capacity
👉 Palletizing for:
✅ boxes in PE bags
✅ boxes in cardboard boxes
✅ individual bags directly on the pallet
The solution allows for the simultaneous running of 2–3 different types of products, with quick recipe changes directly from production and automatic gripper zone configuration.
✅ Significant increase in productivity
✅ Reduction of labor in the end-of-line area
✅ Stable, uniform pallets optimized for storage and transport
✅ Traceability through automatic logistics labeling
✅ Reliable operation even in temperatures between 2 and 40 degrees Celsius
✅ Scalability for higher volumes and new products
Dasstec knows and does
✅ Compact concept, adapted to the space and customer requirements; collaboration with the customer is essential.
✅ Process engineering and end-of-line layout
✅ Industrial robot integration
✅ Design and delivery of transport and stabilization systems
✅ Automation, PLC, HMI, and safety integration
✅ Installation, commissioning, and technical documentation
✅ Logistics flow optimization and workflow and operation ergonomics
✅ Preventive and predictive maintenance already integrated and thanks to the Ethercat architecture, which allows instant access to all process values/variables.
Choose Dasstec, Your Automation Factory