Types of palletizers

Conventional, in-line, robotic, gantry, cobot, hybrid, and manual palletizers compared with real models, rated speeds, footprint, changeover, and prices.

Updated October 2, 2026

A palletizer stacks product on a pallet in a set pattern. It is one part of a larger palletizer system. The type you pick sets your speed, floor space, and how easily you change products. This guide compares each type with real models and the specs their makers publish.

All speeds here are maker ratings. Real output is lower once case size, pattern, and pallet changes come in. Makers also use different units. Cases per minute, picks per minute, layers per minute, and robot cycles per hour are not the same thing. This guide keeps each maker’s unit.

Palletizer types at a glance

A SKU (stock keeping unit) is one product in one pack size. The sources for each row are in the sections below.

Conventional high-level palletizers

A conventional palletizer forms whole layers before they go on the pallet. This is called layer forming. Cases are pushed into rows. Rows are pushed together into a layer. The layer then moves onto the pallet.

On a high-level machine, cases enter at an elevated infeed. Layers form above the pallet. Columbia’s HL4200 has a “bi-parting apron.” That is a plate that opens to drop the layer onto the pallet below. A hoist lowers the pallet one layer at a time.

Rated speeds:

• Columbia rates the HL6200 at “up to 120 cases per minute (depending on pattern).”
• Honeywell rates the Alvey 891i at “up to 70 cases per minute” and the 890i at “up to 45 cases per minute.”
• Regal Rexnord rates the PriorityPal HL Series at “Up to 7 layers per minute.”

Read the full conventional palletizer guide for how each part works.

Conventional low-level palletizers

A low-level or floor-level palletizer forms layers near floor height. Columbia says infeed height is “usually at 36″ above the floor” on its floor-level models. Operators and mechanics can reach most parts without climbing.

Rated speeds:

• Columbia says the FL2000 “palletizes 20 cases per minute or more, depending on case size and pallet pattern.”
• Columbia rates the servo-driven FLD6200 at “speeds up to 100 cases per minute.”
• A-B-C rates the M72A at “3 layers/minute” and the M72AG at “4 layers/minute.”
• Honeywell rates the Alvey 680 at “up to two layers per minute” and the 681 at “up to five layers per minute.”

In-line and single-column palletizers

An in-line palletizer keeps product moving in a straight line. Columbia explains that in-line palletizers “use a continuous flow divider to guide products onto a layer-forming area.” A hoist then lifts the pallet to take each layer. Columbia lists infeed heights of 110″ to 145″ for these machines.

These carry the highest ratings we found:

• Columbia rates the HL9200 at “up to 200 cpm.” That is cases per minute.
• Honeywell rates the Alvey 943 at “up to 180 cases per minute.” It rates the Alvey 944 at “in excess of 225 cases per minute.”

A single-column palletizer moves the layer head up and down one vertical column. OCME lists its Ares as a “Single-column palletizer.” OCME’s page gives no speed.

Robotic arm palletizers

A robotic palletizer uses an industrial robot arm. Most palletizing robots, such as the FANUC M-410iC/185, have 4 axes. Some have 5 or 6. A 4-axis arm swings, reaches, lifts, and turns its wrist. The robot carries a gripper, also called EOAT (end-of-arm tooling). The gripper picks a case, a row, or a whole layer.

Real models:

• FANUC rates the M-410iC/185 at a 185 kg payload, 4 axes, and 3,143 mm reach.
• Yaskawa rates the PL190 at a 190 kg payload and 3,159 mm reach. Yaskawa claims “> 1700 cycles/hour with full payload” on a set test motion that Yaskawa lists as “400 mm – 2000 mm – 400 mm.” That is the robot alone, not a case rate for a full cell.
• Pearson rates its RPC-C robot cell at “Up to 24 cases/min” for cases up to 40 lb.
• TopTier rates its Value Palletizer robot cell at “10-12 cases per minute” for cases up to 200 lb.

A robot can serve more than one line from one cell. It changes patterns in software. Odecopack says a robotic palletizer “can reach further, carry more and cycle faster” than a gantry. Odecopack lists robotic palletizers from $165,000. MMCI lists its “Quick-Ship” robotic palletizers from $175,000. Both are starting prices seen October 2026. Read more in the robotic palletizer guide.

Gantry and cartesian palletizers

A gantry palletizer is a frame over the pallet. A gripper rides on straight rails along three axes. X runs side to side, Y runs front to back, and Z runs up and down. This is why it is also called a cartesian palletizer. It has no robot arm.

How a gantry compares

Odecopack describes its cartesian palletizers as “Built for low- to medium-speed lines.” It says “a gantry covers the pallet beneath it and runs at a steady rate, where a robotic palletizer can reach further, carry more and cycle faster.” Odecopack lists its gantry payload as “Up to 65 lb (32 kg).” 65 lb works out to about 29.5 kg, so ask which figure is the rating.

Gantry models and ratings

Prices were seen October 2026. The Vention listing includes the frame, gantry, infeed conveyor, gripper, safety devices, and deployment support. Check what each quote includes. Freight and site work may still be extra.

When to pick a gantry

Pick a gantry for steady, low to medium case rates. It suits plants that want a small, simple cell. Odecopack’s page lists “First automation projects” as a good use. Odecopack says its own robot cells reach further and carry more than its gantries. That is one maker’s comparison. Check each gantry’s payload. CODI offers a heavy-duty Flex Stack Pro rated “Up to 110 lb (50 kg),” including the tooling. Pick a robot if you need more reach or several lines into one cell.

Cobot palletizers

A cobot (collaborative robot) is a small robot arm with built-in force and speed limits. It is meant to work near people when the application allows it.

• Universal Robots rates the UR20 at a 20 kg (44.1 lb) payload, 25 kg extended, with 1,750 mm reach.
• Robotiq rates its PE20 palletizing kit at “up to 13 picks per minute.” It lifts up to 18 kg (40 lb) and stacks up to 2.15 m (84 in). The footprint is 1,310 × 2,400 mm.

A cobot is not safe near people on its own. Universal Robots says “Cobots alone are not collaborative, only cobot applications can be collaborative.” Collaborative status comes from a risk assessment of the whole application. That covers the gripper, the load, the pallet stations, and nearby people. Current rules are in ISO 10218-2:2025 and its US adoption, ANSI/A3 R15.06-2025. The 2025 editions fold in the collaborative guidance from the older ISO/TS 15066. These are consensus standards, not OSHA rules. The risk assessment may still call for area scanners or fences.

Automation Distribution listed the PE20 kit at $49,429.69 in October 2026. That price excludes the robot and the gripper. Read the cobot palletizer guide.

Hybrid palletizers

A hybrid joins a conventional palletizer with one or more robots. How the work splits depends on the model.

• Honeywell says the Alvey 950 series uses “one or more robotic arms” for “pattern forming” at “more than 125 cases per minute.” It also rates the Alvey 750 hybrid at “speeds to 50 cases per minute.”
• Premier Tech’s APR-1150 is a hybrid bag palletizer. Premier Tech says it “combines” its “conventional palletizing machines and our robotic equipment’s flexibility.” It uses a FANUC M410iB/140H robot, an electric pallet elevator, and alignment bars to square layers. Premier Tech rates it at “Up to 25 units per minute,” or up to 27 with an option, “Based on a standard five bags pattern.” Its typical footprint is 33 ft long × 18 ft wide × 16 to 19 ft high.

We found no public prices for hybrids. See the bag palletizer guide for more on bags.

Manual palletizing and lift assist

At low volume, people still stack by hand. Lift aids make it safer. A pallet positioner keeps the top layer at a good working height. A vacuum tube lifter takes most of the weight. Uline lists its H-8935 spring pallet positioner at $2,195 for loads up to 4,500 lb. See manual palletizing aids.

Footprint and changeover

Footprints come from the Columbia HL4200 cut sheet, A-B-C, Columbia FLD6200 cut sheet, Premier Tech, TopTier, Vention, Robotiq, and Uline. Most footprints leave out pallet stacks, forklift aisles, and the full-pallet exit.

How to pick a type

1. Peak rate. Above about 100 cases per minute, the rated machines we found are conventional, in-line, or hybrid. Below 15 cases per minute, a cobot or gantry may be enough.
2. SKU count. Many SKUs and frequent changes favor robots. Long runs of a few SKUs favor conventional machines.
3. Case weight. Check the heaviest case against the payload. The Robotiq PE20 lifts up to 18 kg. FANUC rates the M-410iC/185 at a 185 kg payload.
4. Floor space and height. In-line machines need tall infeeds. Columbia lists 110″ to 145″.
5. Pallets. Give the supplier your pallet size, type, and condition range. Ask how the dispenser handles a broken or warped pallet. Premier Tech lists a dispenser that “can handle pallets of various sizes and quality” on its APR-1150.
6. Safety. Every type needs guarding under OSHA 29 CFR 1910.212 and a lockout/tagout plan under OSHA 29 CFR 1910.147. Conventional, gantry, and hybrid machines are usually built to ANSI/PMMI B155.1. Robot cells follow ISO 10218-2:2025 and ANSI/A3 R15.06-2025. Never bypass guards, interlocks, light curtains, or area scanners. See palletizer safety.

Next, check palletizer costs and work through the buying guide. The manufacturers list shows who makes each type. To unload pallets instead, see depalletizers.