Mixed Palletizing (On-the-Fly)

Mixed Palletizing of Random SKUs

Build stable mixed pallets directly from random product flows with AnyStack.

No Sequencing. No Downtime.

Progressive Robotics delivers on-the-fly mixed palletizing that adapts to your warehouse’s reality:

variable SKUs, unpredictable infeed, and the speed modern logistics demand.

How On-the-Fly Mixed Palletizing Works

1. Scan

The 3D vision system captures box dimensions and orientation in real time.

2. Think

The AI engine selects the next optimal stacking position using real-time motion planning and physical constraints.

3. Execute

The robot performs a collision-free move, placing the case precisely to form a stable mixed-SKU pallet.

Mixed Palletizing Solutions Designed for Modern
Fulfillment and Smart Warehouses

Turn storage-to-shipping into one continuous flow and streamline your outbound with on-the-fly palletizing

Why Mixed Palletizing Changes Everything

AI-Powered Stacking Engine

Determines the optimal placement for every box on the pallet by considering weight and size.

✔ Millisecond inference
✔ Self-improving algorithms
✔ Guaranteed pallet stability

No Sequencing - No Bottlenecks

Handle random inbound flows directly and still deliver perfect outbound pallets.

✔ Faster cycle times
✔ Reduced footprint and cost
✔ Ideal for e-commerce fulfillment and 3PL

3D Vision & Motion Planning

The robot detects and positions every case dynamically with collision-free paths.

✔ Sub-millimeter detection accuracy
✔ Vision-guided placement validation
✔ Smooth, singularity-free robot motion

Turnkey AnyStack Palletizers

Pre-engineered, fully integrated palletizing cells - ready to deploy.

✔ Fully integrated hardware, software & safety
✔ Installation, commissioning, and support incl.
✔ 2 options: AnyStack Lite & AnyStack Pro

Built for End-Users, Engineered for Warehouse Operators

For End-Users:
(3PLs, E-commerce)

For Automation Partners:

Where Mixed Palletizing Fits Best

1. E-Commerce Fulfillment

Handle unpredictable product assortments with high throughput.

2. 3PL Warehouses

Adapt to multiple SKUs and packaging formats effortlessly.

3. Retail Distribution Centers

Automate outbound palletizing directly after pick & pack.

4. Automated Storage & Retrieval Systems

Seamlessly integrate with AutoStore (AS/RS), and AMR/AGV systems

The Power of Physical AI in Logistics Automation

Automation starts where sequencing ends.

Our on-the-fly palletizer transforms random infeed into stable outbound pallets with Physical AI.

Ready to Unlock True Palletizing Flexibility?

Transform your warehouse outbound process with AI-powered, on-the-fly palletizing.

Reduce engineering overhead, accelerate fulfillment, and future-proof your logistics automation.

Frequently Asked Questions

What is mixed case palletizing?

The process of stacking boxes of different sizes, weights, and SKUs on a single pallet. Traditional systems require sequencing and buffer conveyors to achieve stability.

What is on-the-fly palletizing?

A method where the system eliminates the sequencing step, using AI, computer vision, and real-time motion planning to build stable pallets from random inbound sequences. It’s a breakthrough in warehouse and logistics automation, making smart warehouses truly flexible and cost-efficient.

How does AI improve palletizing?

It calculates optimal stacking positions in real time and learns from each cycle to increase efficiency.

What’s the difference between traditional mixed palletizing and on-the-fly (unsequenced) mixed palletizing?

Traditional mixed palletizing requires sequencers, or pre-sorted product flows to create a stable pallet. On-the-fly mixed palletizing eliminates all pre-sorting requirements. The system uses AI, 3D vision, and real-time motion planning to build stable pallets directly from random inbound boxes. No sequencing, no waiting, and no extra hardware is needed.