A Safer Way to Finish the Job

Reducing repetitive manual handling 

We have installed an autonomous palletising robot at our manufacturing facility as part of ongoing investment in safer and more reliable production. 

At the end of the production lines, finished cartons must be stacked onto pallets ready for shipment. This previously involved repeated lifting and stacking of cartons weighing between 6kg and 17kg throughout the day and had been identified as a higher-risk repetitive manual handling task. 

The new system now carries out almost all pallet stacking automatically inside a guarded enclosure, removing almost all repetitive lifting, twisting and repetitive strain for the production team. 

Supporting the team 

This change does not replace roles. 
Previously, operators rotated through palletising duties due to fatigue. Now the team focuses on running the line, material flow and quality checks while the robot handles the repetitive lifting. 

The result is smoother production with fewer end-of-line delays and longer uninterrupted run time. 

Consistency and reliability 

Automated stacking improves the uniformity of pallet builds, helping stability during storage and transport and reducing re-handling. 

The system was designed specifically to fit the available space and handle multiple product formats, allowing flexibility as production changes. 

Preparing for future demand 

The installation supports higher production demand without increasing physical workload. It forms part of our approach to improve working conditions while maintaining reliable supply for customers. 

Continuing to improve how we work 

This project forms part of our ongoing approach to refining everyday production. By removing repetitive handling tasks, the team can focus on monitoring, quality and keeping the lines running smoothly. 

We will continue to introduce practical improvements that support safe working, reliable output and consistent product quality, helping us meet demand while maintaining the standards customers expect.