ORDER-BASED PALLETIZING SOFTWARE

Fewer Pallets Per Order. Every Constraint Met. Automatically.

RobotStackr OS is mixed case palletizing software powered by StackrBrain AI. Send your complete order — all items, dimensions, weights, and constraints — and receive an optimized stacking plan in seconds. Fewer pallets per shipment, higher fill rates, zero constraint violations.

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Powered by StackrBrain AI — Software only, no hardware required

RobotStackr OS mixed case palletizing software showing optimized multi-SKU pallet configuration

Fewer Pallets

Required per order

Stacking Constraints

Taken into account for each placement

Seconds

Full order optimization time

Any integration

Stacking plan for any carrier, robot & gripper

From Order to Optimized Stacking Plan — In Seconds

RobotStackr OS transforms your complete order data into an optimized stacking plan through three straightforward steps — no complex setup, no manual configuration per order.

RobotStackr OS constraint-aware palletizing
1

Send Your Order

Your WMS or ERP sends the complete order to OS via REST API: all item dimensions, weights, quantities, and any product-level constraints. OS accepts standard data formats — no proprietary input requirements.

2

StackrBrain Optimizes

The AI evaluates all items simultaneously. It determines the minimum number of pallets required, assigns each item to a pallet, and calculates the optimal placement position and stacking sequence — respecting every active constraint.

3

Execute the Plan

OS returns a complete, ready-to-execute stacking plan: which item goes on which pallet, at which position, in which order. Feed this directly to your robot controller or use it to guide manual operators.

Intelligent Constraint Handling

RobotStackr OS enforces every real-world constraint during mixed case palletizing optimization — not as an afterthought, but as a core part of the algorithm.

Weight Distribution

Heavy items placed at the bottom. Maximum pallet weight enforced. Center of gravity optimized for transport stability.

Fragility Rules

Fragile-on-top logic prevents crushing. Configurable fragility levels per SKU ensure delicate items are always protected.

Stackability Codes

Industry-standard stackability codes determine which items can support others. OS respects every code in the optimization.

Orientation Control

Some products must stay upright. Others cannot be rotated. OS respects every orientation restriction in the final plan.

Product Separation

Keep chemicals away from food. Separate product groups on different pallets or different zones. Fully configurable rules.

Height Limits

Maximum pallet height enforced per destination, truck type, or storage location. No overheight loads leaving your facility.

Why StackrBrain Outperforms Traditional Cubing Software

Most mixed case palletizing software uses fixed rules or basic heuristics. StackrBrain uses advanced AI optimization — and that difference shows in fill rates, constraint handling, and adaptability.

Superior Fill Rates

StackrBrain AI evaluates significantly more placement configurations than rule-based systems. The result: more items per pallet, fewer pallets per order, lower shipping costs. The optimization gets better with more data — not worse.

Extreme Constraint Flexibility

Standard constraints like weight and height limits are just the beginning. RobotStackr OS mixed case palletizing software handles fragility rules, orientation restrictions, stackability codes, product group separation, weight distribution requirements, and custom business rules specific to your operation.

Adapts to Product Changes

New product added to your catalog? Changed box dimensions? RobotStackr OS mixed case palletizing software adapts automatically. No manual reprogramming of stacking patterns or placement rules. The AI learns to handle new products the moment it sees their specifications.

Fast Optimization

Despite evaluating thousands of possible configurations, RobotStackr OS mixed case palletizing software returns optimized stacking plans in seconds. Fast enough for real-time order processing in high-volume distribution centers handling hundreds of orders per hour.

REST API Integration

RobotStackr OS mixed case palletizing software connects to your WMS, ERP, or order management system via a standard REST API. Send order data in, receive stacking plans out. Clean, documented, and built for enterprise integration — no middleware or custom connectors needed.

Robot-Brand Agnostic Output

RobotStackr OS mixed case palletizing software outputs a universal stacking plan: pallet assignments, placement coordinates, and stacking sequences. Feed this to any robot controller — FANUC, ABB, KUKA, Universal Robots, Yaskawa, or manual operators.

CONSTRAINT-AWARE

Every Rule Enforced. Every Placement Verified.

Real-world palletizing is full of constraints that software must respect. Heavy items cannot crush fragile ones. Certain products must stay upright. Weight must be distributed evenly for transport stability. Product categories may need separation.

RobotStackr OS does not just ‘try’ to follow these rules — it guarantees them. Every constraint is enforced mathematically before a stacking plan is generated. Zero violations, every time.

  • Some examples:
  • — Maximum pallet weight and height
  • — Item fragility and stackability rules
  • — Orientation restrictions (upright only, no tilt)
  • — Weight-on-weight limits
  • — Product group separation
  • — Weight distribution for transport stability
  • — Family packing
  • — Hazardous item separation
  • — Custom business rules per customer or route
RobotStackr OS mixed case palletizing software showing optimized multi-SKU pallet configuration

Mixed Case Palletizing Software Across Industries

RobotStackr OS serves any operation that ships mixed-SKU pallets. From high-volume 3PL distribution to complex grocery fulfillment — OS adapts to your constraints and product mix.

Grocery warehouse

3PL & Distribution

High-volume outbound operations shipping mixed orders across multiple clients. OS minimizes pallets per shipment, reducing freight costs and dock time. REST API integrates with multi-tenant WMS platforms.

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Grocery & Retail

Store-delivery pallets with complex constraints: glass jars stay on top, heavy beverages on the bottom, aisle-sequencing for efficient store replenishment. OS handles the full complexity of grocery mixed palletizing.

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Manufacturing & CPG

Outbound shipping from production facilities with diverse product portfolios. OS optimizes mixed pallets across hundreds of SKUs with varying dimensions, handling frequent product additions and spec changes automatically.

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Not Sure Which Approach Fits Your Operation?

RobotStackr OS is software for order-based optimization when you control the sequence. RobotStackr OTF is a physical AI module for real-time palletizing when sequences are unknown. Explore both options to see what solution fits best for your proces.

See RobotStackr OTF
Explore StackrBrain
Mixed Palletizing Overview

Frequently Asked Questions

What is RobotStackr OS?

RobotStackr OS is mixed case palletizing software that optimizes complete known orders onto the minimum number of pallets. It is a software product (no hardware) powered by StackrBrain AI. You send your order data via REST API, and OS returns an optimized stacking plan with pallet assignments, placement coordinates, and stacking sequences.

How does OS differ from traditional cubing software?

Traditional cubing software typically uses rule-based or heuristic approaches that follow fixed patterns. RobotStackr OS uses StackrBrain AI to evaluate significantly more configurations and find better solutions — especially for complex mixed orders with many constraint types. It also adapts automatically to product changes without manual pattern maintenance.

What constraints does OS support?

OS supports all common palletizing constraints and can be extended with custom rules: maximum pallet weight and height, item fragility and stackability codes, orientation restrictions, weight-on-weight limits, product group separation, weight distribution for transport stability, and custom business rules per customer, route, or carrier.

How does OS integrate with our WMS?

Via a standard REST API. Your WMS sends order data (item dimensions, weights, quantities, constraints) and OS returns the optimized stacking plan. The API is documented, uses standard formats, and requires no middleware or custom integration projects. Typical integration takes days, not months.

Is OS only for robots or also for manual palletizing?

Both. OS outputs a stacking plan that can be executed by any robot controller or used to guide manual operators with step-by-step placement instructions. The optimization benefit — fewer pallets, better fill rates, zero constraint violations — applies regardless of whether a robot or person does the physical stacking.

What is the difference between OS and OTF?

OS is software that optimizes complete known orders — you send all items upfront and receive the best possible stacking plan. OTF is a physical AI module (IPC) that makes real-time placement decisions for unknown sequences. OS works when you control the item sequence; OTF works when you do not. OS is software-only; OTF includes dedicated hardware.

Ready to Ship Fewer Pallets?

Tell us about your order profiles — typical order sizes, SKU counts, product types, and constraints. We will show you exactly how many pallets OS can save per week for your operation.

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Also explore: RobotStackr OTF — StackrBrain Technology — Integrations