Robot payload and published cycle time do not directly equal palletizing capacity. The complete cell sequence must be studied.
Calculate product arrival
Start with cases or bags per minute for every SKU. Include line variation and short peak periods.
Define picks per cycle
A gripper may pick one product, several products or a complete layer. Larger picks reduce robot cycles but increase tool weight and product-handling complexity.
Include every robot action
Pickup confirmation, travel, placement, slip sheets, tier sheets, tool checks and safe approach paths all consume time.
Include pallet logistics
Empty pallet supply, full pallet discharge and wrapper availability can become the true bottleneck. The cell needs enough accumulation to manage these events.
Check payload at the worst position
Use product plus gripper weight and verify reach at the highest and farthest pallet positions. Dynamic limits may be more restrictive than nominal payload.
Validate with a cycle simulation
The final study should show cycle time by pattern, robot utilization, accumulation assumptions and the effect of pallet exchange.
