Walk through any warehouse today. You’ll likely see workers unloading pallets.
Many facilities still rely on manual labor for this task. Contrary to modern trends, it involves physically demanding work that can lead to injuries, create operational bottlenecks and increase labor costs.
Robotic depalletizing offers a solution. Yet many companies hesitate to adopt this technology. Mainly due to misconceptions about what modern robotic systems can do.
But these mistaken beliefs aren’t just wrong. They are expensive. Let’s examine five common myths about robotic depalletizing, which quite probably might be draining your budget right now.
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Misconception #1Â Robotic depalletizing is only cost-effective for high-volume operations
“We don’t move enough pallets to justify a robot.”
We hear this all the time. However, it’s simply not true anymore.
Today’s market offers solutions for operations of all sizes. Compact systems fit into smaller facilities, while flexible financing options reduce upfront costs. Robot-as-a-Service (RaaS) or other leasing and subscription-based programs make advanced technology accessible to everyone.
Doing the application math is often surprising to people, as they discover that manual depalletizing creates hidden expenses they didn’t imagine or track.
- Â Worker injuries lead to compensation claims
- Â Inconsistent speeds create unpredictable workflows
- Â New generations are hesitant to join labor professions
- Â High resignation rates, increase training costs for new workers
These reasons make us flip the question.
It’s not about whether a facility can afford more automation. It’s whether the management can afford to keep it open and operating without it.
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Misconception #2Â All products require custom end-of-arm tooling
We’ve done our visits and discussions around.
Most people in manufacturing and logistics still believe robotic depalletizing demands expensive custom grippers. A misconception clearly coming from experience with older systems with limited capabilities.
Extensive testing in our palletizing lab and recent installations on the field though, showed that modern end-of-arm tooling has evolved dramatically. Today’s grippers handle multiple product types without frequent changes. Vacuum systems can lift boxes, bags and containers, while adaptive grippers adjust to different shapes automatically.
A robotic arm with a single gripper can often depalletize and feed an entire product line. Before long, factories that have installed such systems confirmed that they have helped them:
- Â Eliminate costly changeovers
- Â Reduce maintenance expenses
-  Simplify production operators’ training
When custom tooling is needed, modern quick-change systems make swaps fast. An operator can change grippers in under two minutes, with no specialized training required.
This versatility of new-gen tooling slashes implementation costs. And it makes robot systems practical for mixed-product operations.
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Misconception #3Â Integration with existing production systems is too complex
“We’d have to rebuild our whole input system to the production line.”
This fear stops many projects before they start. And although it holds some truth in specific cases, it regularly stems from outdated information about integration complexity. That has nothing to do with one’s facility reality.
Based on new generation robotic software, today’s automated depalletizing systems offer plug-and-play simplicity. Standard communication protocols connect with existing equipment. User-friendly interfaces make programming straightforward. Intuitive touchscreens make everyday control a breeze for even the non-tech-savvy operators.
On top of these, most depalletizing robots can be installed in days, not weeks. They are fast to integrate with the warehouse management or manufacturing execution systems (WMS and MES) and can seamlessly communicate with upstream and downstream equipment.
Modern systems can even retrofit into legacy equipment, working alongside existing conveyors and sorting systems. This gradual approach makes automation accessible to facilities of any age.
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Misconception #4Â Robotic depalletizing can’t handle different types of loads
Shocking as it was to find out, many people still assume that robots can only handle perfect pallets. This might have been true ten years ago. Today’s systems – however – are more sophisticated and with functionalities which can be extended to satisfy complex application specifications.
Advanced vision technology identifies products in real-time. It helps the depalletizing systems detect broken patterns and recognize shifted or damaged boxes quickly. Hence, the robots adjust their approach accordingly.
New-gen software includes machine learning capabilities that improve over time. The system learns from unusual situations and becomes more adaptable with each pallet it processes.
Handling mixed pallets? Not a problem, too. Modern robots identify different products automatically and sort them while depalletizing. They can handle various heights, shapes and weights without confusion.
To top it off, even damaged products won’t stop modern depalletizing systems. Vision technology identifies problems and informs the robot instantly. It then adjusts grip position to compensate and maintains throughput despite imperfect conditions.
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Misconception #5Â The technology Is still too expensive to justify
“The price tag scared us away.”
Investigating these reactions further, we usually discover that people ignore the complete financial picture. In robotic depalletizing systems, initial cost is just one factor in the equation.
A true cost calculation includes many variables:
- Â Â Labor savings accumulate monthly
- Â Â Error reduction prevents damaged products
- Â Â Consistent throughput improves planning accuracy
All these factors contribute to a more positive and shorter Return-of-Investment (ROI).
Additionally, modern systems use less energy than previous generations. They may even be powered by single phase power lines, in case of collaborative robots and loads lighter than 25 kilos.
Their components also last longer with less maintenance, while their software can be updated wirelessly and automatically, without service calls.
Flexible financing options can make budgeting easier. Operating leases and subscription-based models convert capital expenses to operating costs. Thus, payment plans can align with a specific facility’s cash flow needs.
Given the data and industry knowledge, we must look beyond direct labor replacement.
- Â Â Robotic depalletizing creates unexpected benefits
- Â Â Production scheduling becomes more precise
- Â Â Warehouse space utilization improves
- Â Â Workers move to higher-value tasks
In quite a few cases, the indirect benefits can exceed the direct labor savings significantly.
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What’s today’s reality in manufacturing and logistics depalletizing?
Outdated beliefs can cost money every day. Modern robotic depalletizing has evolved dramatically and it’s altogether more affordable, flexible and capable than many realize.
If you’ve been one of those until today, we suggest you:
- Â Â Proceed with a realistic assessment of your depalletizing operations
- Â Â Calculate the full cost of your current processes
- Â Â Include all factors in your evaluation
The results might surprise you.
Robotic technology advances rapidly. Early adopters gain competitive advantages, as they reduce costs while improving reliability. Let alone, they future-proof their operations.
If you were on the fence, maybe it’s time you took action. Complete the above calculations and contact an application-savvy solution provider to help you further your project budgeting and planning.
At Progressive Robotics we’ve been working on optimizing robotics depalletizing and have built intuitive software, which is easy to install and operate. Contact us and we will run together a full demo for your own applications.
And don’t forget.
The only true mistake in modern business is allowing misconceptions to prevent your progress.