Building an Automated Palletizer for Mixed Parcel Stacking:
Unlock The Power of 3 Elements

May 2023


In today’s rapidly evolving world, automation has become an indispensable tool for improving efficiency and productivity and overcoming labor shortage in various industries. One such application is the mixed case palletizing, a task that traditionally required manual labour and consumed valuable time. However, with the convergence of cutting-edge technologies, we now have the power to streamline this process through the integration of three key elements: vision, AI algorithms, and robotics. In this blog post, we will delve into the significance of each element and how they work together to revolutionize parcel stacking by creating an automated palletizer. 

Vision: The Eye that Scans the Parcels

The first essential component of automating mixed parcel stacking is vision. A camera-based system, equipped with advanced imaging and recognition capabilities, acts as the “eye” in this process. By scanning the parcels, the vision system can extract crucial information such as size, shape, weight, and even barcodes or labels such as “this side up” or “fragile”. This real-time data capture enables precise identification and characterization of each parcel, forming the foundation for subsequent automation steps. At Viroteq we use the StackrScan system to integrate with many types of 3D cameras. You can even use it to connect to your ERP or WMS system to retrieve additional parcel data.

Stacking Algorithm: The Brain Behind Precision Placement

Once the vision system has analysed and extracted the necessary information from the parcels, the next element in the automation trio comes into play: the placement algorithm. This algorithm serves as the intelligent brain behind the entire process. By leveraging the data provided by the vision system, the algorithm can calculate the ideal placement positions of each parcel on the pallet. It takes into account various factors such as size, weight distribution, fragility, and uses a model of the physical setup to make sure the robot is able to reach its goal efficiently and without collisions. The algorithm’s calculations ensure efficient utilization of space while maintaining stability and structural integrity, optimizing the stacking process. Viroteq has developed its own state-of-the-art StackrBrain technology, embracing the power of deep learning. This StackBrain algorithm is trained on millions of stacking patterns and can determine the best parcel location on-the-fly without any pre-knowledge of the upcoming parcels. This makes sure that even when parcels can’t be buffered or re-ordered, still the most efficient and stable result is achieved. To learn more about this StackrBrain algorithm, visit our product page

Pick and Place Robots: The Hands that Places the Parcel

With the precise instructions generated by the algorithm, the final element in the automation trio, pick and place robots come into action. A picking robot equipped with specialized grippers and precise motion control is employed to execute the physical manipulation of the parcels. By following the trajectory calculated by the algorithm, the robot can accurately identify the optimal gripping points and carefully lift and place each parcel onto the pallet. The robot’s dexterity and repeatability make it an ideal solution for handling mixed parcels with varying sizes, shapes, and weights. Using a pick and place robot means no downtime, no sick days and around the clock operation. Viroteq’s RobotStackr system is brand agnostic and can be used with any type of pick and place robot or cobot.

pack and place robot

The Synchronization of Elements: Seamless Automation

The true power of automating mixed case palletizing lies in the seamless synchronization of these three elements: vision, AI stacking algorithm, and robotics. The vision system scans the parcels, providing real-time data that feeds into the algorithm. The algorithm then processes this data, calculating the precise placement positions and optimizing the stacking patterns. Finally, the robot follows the trajectory provided by the algorithm, executing the physical manipulation of the parcels. This synchronized workflow ensures efficient and accurate stacking, eliminating human errors and significantly reducing time and labor costs. 


Automation has proven to be a game-changer in many industries, and mixed case palletizing is no exception. By combining the capabilities of vision systems, advanced AI algorithms, and robotics, businesses can achieve higher efficiency, productivity, and accuracy in their parcel stacking operations by using an automated palletizer. The integration of these three elements revolutionizes traditional manual processes. It enables organizations to streamline their logistics, reduce costs, and meet the ever-increasing demands of the modern world. As technology continues to advance, we can expect further advancements in this field, making automation an indispensable tool for parcel stacking and many other areas of operation. Find out more about the RobotStackr automated palletizer system to see how Viroteq uses vision, AI and pick and place robots to automate mixed parcel stacking with efficiency exceeding human capabilities.  

automated palletizer