AI-POWERED PALLETIZING MODULE
RobotStackr OTF palletizing software is a purpose-built AI module that integrates into any robotic palletizing cell. It calculates optimal placement positions and collision-free motion paths for every incoming box — in real time, within a single robot cycle. No pre-programming. No pattern teaching. Just plug in and palletize.
Powered by StackrBrain AI
Plug n Play
IPC + StackrBrain stacking software
Any
Robot brand, gripper, and carrier type
L x W x H
Minimum input needed per box
24/7
Autonomous continuous operation
THE PRODUCT
RobotStackr OTF is a custom-built Industrial PC optimized specifically for real-time AI stacking calculations. The module integrates directly into your existing robot cell — regardless of robot brand, gripper type, or carrier format.
For every incoming box, StackrBrain calculates two things simultaneously: the optimal placement position on the carrier, and a collision-free, cycle-time-optimized motion path for the robot arm. All constraints are evaluated in real time — product characteristics, robot self-collisions, hardware collisions, and collisions with the existing stack.
The result: autonomous mixed case palletizing that runs continuously, with minimal input. All StackrBrain needs to start is the length, width, and height of each box.
Every cycle, the same six-step process executes in milliseconds. No human intervention. No lookup tables. Pure AI decision-making.
A product reaches the pick position from conveyor, AGV, or buffer
Dimensions, weight, and orientation are captured automatically
The RL agent analyzes current pallet state and all placement options
Position, rotation, and layer are chosen to maximize stability and density
Placement command is sent to the robot via standard communication protocols
The cycle repeats instantly. No delay, no buffering, no queue required
Every robot cycle, StackrBrain performs a complete optimization — evaluating placement, motion, constraints, and efficiency in milliseconds.
Optimal Placement Position
StackrBrain evaluates thousands of possible positions on the carrier and selects the one that maximizes volume efficiency while maintaining stack stability. This decision accounts for the current state of the stack, the box dimensions, and all active constraints.
Collision-Free Motion Path
Beyond placement, StackrBrain calculates the complete robot trajectory — ensuring the arm, gripper, and box avoid collisions with the cell structure, conveyors, the carrier, and the existing stack. This is not a simple point-to-point move.
Cycle-Time Optimization
The motion path is not just collision-free — it is optimized for speed. StackrBrain minimizes unnecessary movements and accelerations, keeping the robot moving at maximum safe speed throughout the entire pick-and-place cycle.
Product Constraint Handling
Every box can have unique characteristics: weight limits, fragility rules, orientation restrictions, stackability codes. StackrBrain enforces all constraints per product, per placement — automatically, without manual rule configuration per SKU.
Multi-Carrier Support
The same OTF module handles pallets, rollcages, bins, and custom carrier formats. Switch between carrier types without reprogramming. StackrBrain adapts its placement strategy to the geometry and constraints of each carrier.
Stability & Volume Optimization
StackrBrain can be configured to prioritize volume efficiency, stacking stability, or a custom balance between both. The optimization goal can be adjusted per project, per carrier, or per product group.
INTEGRATION
Every palletizing operation is different. That is why Viroteq does not just ship an IPC — we work with your team to find the optimal integration strategy for your specific process.
This includes advising on buffer positions (how many boxes should be queued before the robot), lookahead strategies (how far ahead can the system see what boxes are coming, and how much does that improve stacking quality), conveyor layout, and carrier changeover procedures.
The goal is not just to automate palletizing — it is to maximize the performance of your entire end-of-line process.
RobotStackr OTF is completely hardware-agnostic. The same module works across all major robot brands, gripper types, and carrier formats — without modification.
Robot Brands
FANUC, ABB, KUKA, Universal Robots, Yaskawa, Staubli — and any other brand that supports standard IPC communication. No vendor lock-in. Switch robots without changing your palletizing intelligence.
Gripper Types
Vacuum grippers, clamp grippers, fork grippers, custom end-effectors. StackrBrain accounts for the gripper geometry in every collision check and motion path calculation.
Carrier Formats
Standard euro pallets, block pallets, rollcages, bins, custom containers. StackrBrain adapts placement strategy and constraints to the specific carrier geometry.
From inbound receiving to high-speed production lines, RobotStackr OTF adapts to your operation — not the other way around.
Inbound Receiving
Boxes arrive from conveyors in unpredictable sequences. OTF palletizes every item as it comes — no sorting, no buffering required. The AI adapts to whatever arrives next, building stable and space-efficient stacks regardless of the incoming mix.
End-of-Line Palletizing
High-speed production lines with continuous product flow. OTF keeps pace with line speeds, calculating placement and motion paths fast enough to never become the bottleneck. Works with any conveyor layout and multiple parallel lines.
Multi-Carrier Operations
Operations that switch between pallets, rollcages, and bins throughout the day. OTF adapts to each carrier format without reprogramming. One module handles all your carrier types.
Viroteq offers two palletizing products for different scenarios. OTF handles unknown sequences in real time. OS optimizes when the full order is known upfront.
| RobotStackr OTF | RobotStackr OS | |
|---|---|---|
| Product type | AI module (IPC + software) | Software only |
| Sequence knowledge | Unknown — box by box | Full order known upfront |
| What it calculates | Placement + collision-free motion path | Optimal pallet configuration |
| Best for | Inbound receiving, conveyors, mixed lines | Outbound shipping, order fulfillment |
| Carrier types | Pallets, rollcages, bins, custom | Pallets |
| Robot integration | Direct robot control via IPC | Provides stacking plan for execution |
What exactly is RobotStackr OTF?
RobotStackr OTF is a purpose-built AI module consisting of a custom Industrial PC (IPC) that integrates into your existing robot cell. It runs StackrBrain, our proprietary AI core, which calculates optimal placement positions and collision-free motion paths for every box in real time — within a single robot cycle.
What information does OTF need per box?
At minimum, OTF needs the length, width, and height of each box. This can come from a 3D camera measurement or from your WMS/database. Additional information like weight, fragility, and orientation rules improves stacking quality but is not required to start.
Which robot brands and grippers are compatible?
All of them. RobotStackr OTF is completely hardware-agnostic. It works with FANUC, ABB, KUKA, Universal Robots, Yaskawa, Staubli, and any other brand that supports standard IPC communication. Gripper type does not matter — vacuum, clamp, fork, or custom. StackrBrain accounts for gripper geometry in collision calculations.
Does OTF only work with pallets?
No. OTF supports any carrier type — standard pallets, rollcages, bins, and custom containers. The placement strategy and constraints adapt automatically to the carrier geometry. You can switch between carrier types without reprogramming.
How does Viroteq help with integration?
We do not just deliver hardware. Our team works with you to find the optimal process integration: where to place buffers, how to configure lookahead (seeing upcoming boxes in advance), how to arrange conveyors, and how to handle carrier changeovers. The goal is to maximize the performance of your entire end-of-line process, not just the palletizing step.
What is the difference between OTF and OS?
RobotStackr OTF is a physical AI module (IPC) for real-time palletizing in unknown-sequence scenarios — it calculates placement and motion paths on the fly. RobotStackr OS is software-only for order-based palletizing where the full order is known upfront. Choose OTF when boxes arrive unpredictably; choose OS when you control the sequence.
Edge-based AI palletizing for deterministic production lines with sub-100ms pattern calculation.
Learn more →Vision-guided palletizing with real-time 3D product recognition and quality verification.
Learn more →AI-powered depalletizing for automated layer and random depalletizing operations.
Learn more →StackrBrain is the AI core behind all Viroteq palletizing products. Trained on millions of simulated stacking scenarios, it delivers the intelligence that makes autonomous mixed case palletizing possible.
Tell us about your operation — robot brand, product mix, throughput requirements. We will assess whether OTF is the right fit and how to integrate it for maximum performance.
Also explore: RobotStackr OS — StackrBrain Technology — Integrations
