Robotic Layer Mixed Case Palletizer

NūMove’s Robotic Layer Mixed Palletizer is designed to handle complete layers of mixed products with a throughput of up to 2000 cases per hour with one robot! This solution builds stable pallets, accommodating varying product formats and sizes within each layer while minimizing the number of top-off cases. An advanced software optimizes the product placement on the pallet and determines the best pattern for each layer. Closed cases, wrapped trays, unwrapped trays and bottles in returnable shells can be palletized on various pallet formats (standard 40x48, beverage 37x37, half pallets, etc.). | RAPTOR (Robot Arm Picking to Order Release) is an advanced automation solution developed by NūMove Robotics & Vision in partnership with KPI Solutions to transform the preparation of mixed-SKU order pallets for high-volume beverage and beer distribution centers. This dual-robot system combines AI-driven vision technology, adaptive tooling, and intelligent software integration to address one of the most labor-intensive challenges in modern warehousing. RAPTOR benefits include: faster order fulfillment for mixed pallets, reduced labor dependence, increased worker safety from reduced repetitive lifting, and increased order throughput. The process begins with robotic depalletizing, where a high-speed robot equipped with proprietary 3D vision and AI algorithms identifies and localizes individual products on donor pallets, even when packaging graphics change. Products are then organized by SKU into dedicated buffer lanes within a flow rack. This temporary storage helps maximize uptime and improve overall throughput. The robot’s end-of-arm tool integrates vacuum, bottom support, and top clamping to handle diverse packaging formats such as closed cases, open-top cases, wrapped trays, and carton boxes in trays. For returnable shells containing loose bottles, detachable connectors are automatically added to ensure secure handling. This design enables high-speed operation while maintaining product integrity. On the opposite side of the buffer flow rack, a second robot performs robotic palletizing, retrieving items one at a time to build dense, stable mixed-SKU pallets. Its gripping system mirrors the depalletizer’s versatility, preventing drops even with damaged packaging. Advanced cubing software determines optimal pallet layout, applying stacking rules for product type, size, and weight to meet store requirements. The palletizing robot then retrieves items from the buffer in the precise sequence calculated by the cubing algorithm to build a dense and stable order pallet. RAPTOR also accommodates starter pallets with pre-built layers, using vision technology and AI to verify layer integrity and measure height for precise stacking. A key differentiator of RAPTOR is its seamless integration with KPI Solutions’ Opto™ Software, which acts as the link between the distribution center’s WMS and the robotic system. Opto’s Warehouse Execution System (WES) orchestrates real-time order management, SKU prioritization, and robotic task sequencing, ensuring RAPTOR operates in perfect harmony with upstream and downstream processes. This integration delivers significant benefits: dynamic order release based on demand, real-time visibility through intuitive dashboards, and scalable architecture that adapts to changing SKU profiles and multi-site deployments.