How European Food Manufacturers are Automating Palletizing Without Increasing Workforce Size

Across Italy and the DACH region, food manufacturers are facing the same reality:

• 📈 Increasing production demand
• 👷 Labor shortages and rising costs
• ⚠️ End-of-line processes limiting throughput

And more often than not, the bottleneck isn’t where you think.

👉 It’s palletizing.

The challenge: Scaling without hiring

A premium Italian manufacturer of chocolate, pastries, and snacks recently faced this exact situation.

Their setup was simple — but limiting:

• 1 operator per palletizing station
• €40,000/year labor cost
• 1 shift, 1 line

Scaling production meant only one thing:
➡️ Hiring more operators

But in today’s labor market, that’s:

• Expensive
• Unreliable
• Hard to sustain long-term

So they asked a better question:

👉 “How can we increase output without increasing labor?”

The application: typical (and challenging) food industry constraints

This wasn’t a niche use case. It’s exactly what many manufacturers deal with daily:

• 📦 Cardboard boxes up to 17 kg
• ⚡ 6–10 picks per minute
• 📏 Pallets up to 1,700 mm
• 🧩 Interlayers required
• 🔄 Boxes arriving via conveyor, consistently oriented

In other words:

👉 Too demanding for manual scaling
👉 But traditionally seen as too complex for flexible automation

The solution: Robotiq Lean Palletizing (PE20 model)

Instead of going with a rigid, high-cost automation system, the manufacturer selected:

👉 Robotiq PE20

Because it’s designed specifically for manufacturers who need:

✅ Fast deployment

No major layout changes. No long integration cycles.

✅ Safe collaboration

Operate without fencing — ideal for existing production environments.

✅ flexibility

Handle multiple SKUs, box sizes, and pallet patterns without re-engineering.

✅ Ease of use

Operators can run the system without robotics expertise.

The results: Immediate ROI and scalable growth

💰 €40,000 saved per year — per station

By removing one manual palletizing role:

• Labor costs dropped instantly
• Payback became highly predictable

📈 Increased throughput

With a stable pick rate of 6–10 picks/min:

• No more end-of-line bottlenecks
• Production can scale with confidence

📦 Better pallet quality

• Consistent stacking
• Integrated interlayer handling
• Reduced product damage

🔄 Future-proof operations

As production evolves:

• New products? No problem
• New formats? Easily configurable
• New demands? Already covered

Why this matters for Italian & DACH manufacturers

If you’re running a food production line in:

🇮🇹 Italy
🇩🇪 Germany
🇦🇹 Austria
🇨🇭 Switzerland

You’re likely dealing with:

• High labor costs
• Workforce shortages
• Pressure to increase efficiency

👉 The reality:
Manual palletizing doesn’t scale anymore.

👉 The opportunity:
Automation doesn’t have to be complex or risky.

The smartest first step in automation

Many manufacturers think they need to automate entire lines.

But in reality:

👉 Palletizing is often the fastest, lowest-risk entry point into automation

• Quick ROI
• Minimal disruption
• Immediate impact

Is your application a good fit?

Not every palletizing setup is the same.

The real question is:

👉 Will this work for your boxes, your rates, your layout?

Try the Palletizing Fit Tool (2 Minutes)

Get a clear answer instantly:

• ✔️ Check if your application is compatible
• ✔️ Estimate ROI based on your inputs
• ✔️ Get a recommended configuration

👉 Start your evaluation now with the Palletizing Fit Tool

The post “How food manufacturers in Europe are automating palletizing without adding headcount” by Alessio Cappellaro was published on 04/07/2026 by blog.robotiq.com