Palletizing-Depalletizing Robotics: The Changing Face of Modern Distribution Centers

Palletizing and depalletizing functions in a distribution center (DC) have evolved along a continuum from manual to fully robotic operation. Two major trends are directly impacting the palletizing and depalletizing functions in modern DCs: the proliferation of SKUs and the shortage of qualified, reliable labor.

Consumers demand more choices in their brick and mortar stores. Therefore, DCs have to handle significantly more SKUs with a much wider variety of sizes, colors, shapes and weights. Grocers, convenience stores, restaurants, pharmacies, and even big-box stores contend with limited back-room storage space and highly specific planograms. So, they order smaller loads more frequently and items need to be delivered in aisle-ready condition.

Additionally, DCs face a shrinking labor pool as fewer workers choose jobs involving repetitive tasks, heavy lifting, and uncomfortable working conditions. High turnover rates result in lost productivity and increased costs for training replacements. Wages in general are rising, especially for the type of labor required in DCs. Insurance and worker compensation expenses add to the payroll cost.

These two trends — plus technology that’s now available to address these challenges — have driven DCs to take a new look at robotic palletizing and depalletizing solutions.