◢ COBOTCOST.COM
APPLICATION

Palletizing and case-packing

End-of-line stacking. Cobot picks finished cases from a conveyor and stacks to pallet pattern. Replaces stand-up operator work that's hard to staff.

Installed cell cost
$85-$160K
Payback
10-18 mo
FTEs displaced
1-1.5
Leading cobots
4 models
ON THESE FIGURES

The fastest published payback of the four applications AMD Machines covers. AMD attributes part of the case to turnover: palletizing positions often see 40 to 60 percent annual turnover, at $4,000-$8,000 to recruit and train each replacement.

01 / OPERATIONAL SHAPE

What this application actually is.

Palletizing is the cobot category's fastest-growing application in 2025-2026, driven by tight labour markets for stand-up shift work. Cells pick cases (typically 5-25 kg) from a conveyor and stack to a programmed pallet pattern. Throughput typically 5-12 cases per minute. Cobot palletizing cells are visibly easier to justify than machine tending in 2026 because (a) the displaced operator role is increasingly hard to staff, and (b) Robotiq's Palletizing Solution and FANUC's PalletPRO PRP software reduce programming time from weeks to days. The cohort sweet spot is UR20 / FANUC CRX-25iA / Doosan H2515 at 20-25 kg payload, with UR10e covering lighter case work.

02 / LEADING COBOTS FOR THIS APPLICATION

Which cobot fits, and why.

01Universal Robots UR20
20 kg · 1750 mm · $65,000-85,000
Robotiq Palletizing Solution is URCap-native; UR20 + Robotiq is a near-turnkey palletizing cell. Faster cycle times than UR16e at same Solution licence.
02FANUC CRX-25iA
25 kg · 1889 mm · $60,000-85,000
PalletPRO PRP software is FANUC-native and covers most pallet patterns out-of-box. 8-year service moat compounds at multi-shift palletizing.
03Universal Robots UR10e
12.5 kg · 1300 mm · $45,000-60,000
Lighter cases (5-12 kg). URCap palletizing software has more pre-validated configs for this payload bracket than any other cohort vendor.
04Doosan Robotics H2515
25 kg · 1500 mm · $60,000-75,000
Cost-sensitive alternative for the 20-25 kg bracket. Trade-off is North American integrator depth versus UR / FANUC.
03 / THE KILLER LINE ITEM

The cost most buyers underestimate.

Pallet-stack handling + conveyor integration
$25,000-$60,000

The cobot is half the cell. Pallet positioning, empty-pallet feed, stretch wrap, conveyor infeed — these add up fast. Most buyers underestimate this line by 30-50% on first quote.

04 / NO-PAYBACK FAILURE MODES

How palletizing and case-packingcells don't earn back.

!
Single-pallet cells without buffer
If the cobot pauses to wait for an empty pallet, throughput collapses. Buffer pallet stations are non-negotiable.
!
Mixed case sizes without vision
Variable case dimensions need 3D vision ($15-35K) or upstream sorting. Cells that try to handle 2+ case sizes without it stall on pattern conflicts.
!
Cobot cycle time at human-equivalent
Cobot palletizing is typically 5-12 cases/min. A skilled operator runs 12-18 cases/min on light cases. Payback math requires honest cycle comparison.
OTHER APPLICATIONS
Machine tending (CNC load / unload)Welding (MIG / TIG)Quality inspectionAssembly and dispensing
Source: https://amdmachines.com/blog/cobot-payback-period/ · Payback, installed cell cost and FTE displacement are transcribed from AMD Machines' published payback scenarios (March 2026) where that source covers the application. Wage anchors are BLS CES and ECEC. The line-item costs in sections 03 and 04 are our own estimates, flagged as such, not published prices. Checked 2026-10-02.