Emerging technologies are reshaping the market

In 2025, the bulk of these applications were robotic palletizing and depalletizing, which represented 83% of the total robotic picking market. This is a relatively mature application segment, with robotic palletizing and depalletizing having been used in warehousing for several decades, including in large-scale automation deployments. However, the market structure is expected to shift gradually over time.

By 2030, the combined share of robotic palletizing and depalletizing is forecast to decline to approximately 58% of the total robotic picking market, as newer applications such as bin-to-bin picking and robotic trailer unloading gain traction. “During our forecast period, robotic bin picking is projected to grow at a 36% CAGR from 2026 to 2030, while robotic trailer unloading is forecast to grow at 64% CAGR over the same period,” says senior analyst Irene Zhang.

Robotic bin picking and robotic trailer unloading

Robotic bin picking’s integration into modular solutions has lowered integration complexity, increasing customers’ willingness to deploy. As an add-on solution, robotic picking systems need to integrate with existing workflows, as well as with WMS or WES, which poses an adoption challenge for warehouse operations. “We are seeing a trend toward modular solutions that lower the complexity of integration, with examples including AutoStore’s built-in picking solution – VersaAI Workstation, and Ocado’s on-grip picking,” says Zhang.

Robotic trailer unloading, with its relatively standalone solution and addresses a segment where customers have an urgent need for automation. “On one hand, we see large orders emerging in this market, which improves customer confidence in the maturity of the technology,” says Zhang. “For example, DHL announced plans to deploy more than 1,000 additional Boston Dynamics Stretch robots globally, building on Stretch’s initial use for trailer unloading. UPS has also reportedly planned to invest around $120 million in approximately 400 Pickle robots for truck unloading, highlighting the growing interest in automating one of the most labour-intensive processes at the warehouse dock.

“Our own Voice of Market research points in the same direction: 43.4% of respondents identified receiving and unloading as a priority workflow in their automation roadmap.”

Palletizing evolving beyond traditional applications

Even within the relatively mature palletizing segment, the market is evolving. In recent years, we have seen growing interest in inbound palletizing, where floor-loaded shipments are palletized after unloading before being moved into storage. This reflects the increasing demand for automation across inbound warehouse processes, rather than focusing solely on outbound palletizing. The growing number of partnerships and technology collaborations also highlights this shift. Recent examples include Pickle and Ambi Robotics, as well as the Boston Dynamics and Jacobi Robotics demonstration at 2026 MODEX, highlighting how robotic unloading and palletizing are increasingly being combined into integrated solutions.

How is the competitive landscape evolving?

“We’re seeing a corresponding shift in the competitive landscape,” says Zhang. “Specifically, we’re seeing shifting shares in robotic bin picking, with vendors offering trailer unloading robots accounting for a larger share of the overall robotic picking market.

“Emerging robotic bin-picking providers are gaining share from the early pioneers in the market. Companies such as Ocado, Nomagic, and Sereact are gradually increasing their presence in the robotic bin-picking market and capturing a growing share as adoption expands. Trailer unloading is also creating new opportunities for market share growth. The rapid growth of robotic trailer unloading is reshaping the competitive landscape. As this application expands, companies offering trailer unloading solutions are naturally gaining a larger share of the overall robotic picking market.

“Overall, robotic picking is gaining greater visibility and acceptance across the warehouse automation space,” she concludes. “As adoption expands beyond traditional palletizing and depalletizing applications, robotic picking is expected to become an increasingly important component of warehouse automation. We forecast that by 2030, robotic picking will account for 10% of the total warehouse automation market, up from just 5% in 2025.”

As aerospace manufacturers prepare for significantly increased production rates on future aircraft programmes, the industry faces growing pressure to deliver larger volumes of complex composite structures while maintaining the highest standards of precision and quality. Loop Technology’s FibreLINE system – with the FANUC M-2000 robot at its heart – has been developed specifically to meet these challenges, offering a scalable and highly automated solution for the production of large composite aerostructures.

Founded in 1998, Dorset-based Loop Technology has established a strong reputation for delivering advanced manufacturing solutions across demanding industrial sectors. The development of FibreLINE originated from early involvement in composite wing development programmes and collaborative aerospace research initiatives, where the need for more efficient and scalable composite manufacturing processes became increasingly evident.

Addressing the challenges of composite production

Manufacturing primary aerospace composite structures requires exceptional positional accuracy, often to within ±1 mm, while handling large and complex components. Production environments must also accommodate the combination of delicate composite materials and heavy tooling, creating significant demands on automation systems.

Traditional gantry-based solutions can struggle to provide the flexibility, scalability and cost efficiency required for future aerospace production rates. To overcome these limitations, Loop Technology sought a robotic platform capable of combining high payload capacity with exceptional accuracy and repeatability.

One of the world’s highest-payload articulated industrial robots, the FANUC M-2000 offers exceptional rigidity and high payload capability, enabling FibreLINE to perform demanding manufacturing processes on large aerospace structures without compromising on accuracy. When combined with Loop Technology’s advanced vision systems, photogrammetry technologies and integrated motion control, the platform consistently achieves accuracy levels of around 1 mm across large-scale components.

The result is a manufacturing solution that combines strength, precision and flexibility, enabling aerospace manufacturers to automate complex processes that were previously difficult to scale economically.

Enabling high-rate aerospace manufacturing

The aerospace sector is increasingly focused on future single-aisle aircraft programmes that are expected to require production rates of up to 80 to 100 aircraft per month.

Meeting these ambitious targets using conventional composite manufacturing methods would typically require extensive factory floor space and multiple production machines. FibreLINE offers a significantly more efficient alternative.

A single FibreLINE system can achieve the equivalent output of between five and ten conventional manufacturing machines, helping manufacturers reduce factory footprint, capital investment and operational complexity while increasing throughput and productivity.

A new era for composite aerospace production

The collaboration between Loop Technology and FANUC demonstrates how advanced robotics is enabling a step change in aerospace manufacturing, helping manufacturers unlock new levels of efficiency and competitiveness.

By combining Loop Technology’s expertise in automation and composite production with the strength and performance of the FANUC M-2000 robot, manufacturers can achieve the scalability required for next-generation aircraft programmes while maintaining the precision and quality standards demanded by the aerospace industry.

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The system leverages Comau’s MyCo collaborative robot with a ROS2-based software architecture and integrates intelligent sensors and an advanced modular gripper to autonomously manage picking, handling, and palletising tasks across variable product flows.

Comau’s role within the MASTERLY project reflects its use of advanced AI-backed automation to address evolving production challenges, including increasing variability, supply chain disruptions, and the need for rapid reconfiguration. Indeed, the intelligent warehousing and logistics solution, developed in collaboration with the project’s ecosystem of technology partners, underscores the importance of scalable and versatile automation designed to improve workplace ergonomics, reduce physical strain and enhance operational flexibility within human-centric production environments.

The project parameters were driven by Decathlon’s operational requirements within the targeted fulfilment process, which has provided the foundation for implementing and validating several advanced functionalities. Key partners included Decathlon itself and STAM, a Genoa-based systems integrator, alongside the broader MASTERLY consortium.

In addition to the MyCo collaborative robot and intelligent gripper, engineered to manipulate objects varying in shape, weight, and material, the solution incorporates advanced sensors, vision-based object recognition, digital twin capabilities, and workflow orchestration tools. As a result, it can easily manage the rigid, soft, and porous materials commonly found in e-commerce fulfilment environments.

The system also grants real-time optimization and seamless interaction between operators and the automated processes, ensuring high flexibility while maintaining consistent throughput and operational reliability.

Furthermore, the knowledge gained and functionalities validated during the project will contribute to the continued evolution of Comau’s MyCo collaborative robotics platform and are expected to become part of its broader portfolio of advanced intralogistics capabilities.

“Comau’s role in the MASTERLY project is fully aligned with our commitment to advancing next-generation manufacturing by promoting reconfigurability, efficiency, and human-centric automation,” explains Alessandro Piscioneri, Head of Product and Solution Management – Advanced Automation Solutions at Comau.

“The project also highlights the strategic value of combining intelligent robotics, digital technologies and systems integration to create highly flexible logistics and fulfillment operations capable of adapting to rapidly changing production and market demands while maintaining operational continuity, scalability and ease of use. Comau’s growing strategic focus on intralogistics includes strengthening our capabilities through acquisitions, including Automha and Invent, which enable us to deliver increasingly integrated and intelligent solutions across the entire warehouse and production value chain.”

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Providing up to 4N (0.9lb) of clamping force and 500µm of jaw travel with opening width up to 1.9mm, the new gripper securely holds small optical components during high-dynamic positioning and alignment processes.

As photonics manufacturing becomes increasingly automated, positioning an optical component is only part of the challenge. Fibres, lenses and other miniature components must also be picked up and held with sufficient rigidity to prevent unwanted motion during rapid scanning and alignment. At the same time, the gripping force must be controlled to avoid damaging delicate components.

The P-606.1P micro-gripper addresses these requirements with a monolithic flexure design, piezoelectric actuation, and an integrated piezoresistive force sensor. The combination provides fast response, high structural stiffness and controlled gripping force in a compact package suitable for integration with precision positioning and photonics alignment systems.

The gripper is particularly suited for active alignment processes where an optical component must remain mechanically stable while the positioning system performs rapid scanning or optimisation routines. High structural rigidity helps minimise relative motion between the gripper and component during acceleration, settling, and alignment.

With a clamping force of up to 4N, the P-606.1P can securely hold optical components and fixtures while its piezoelectric drive provides fast, precise jaw motion.

At the core of the P-606.1P is a monolithic flexure mechanism. Flexure guidance eliminates conventional bearings, providing friction-free motion without mechanical play.

Interchangeable jaws allow the gripping interface to be adapted to different component geometries and manufacturing processes. This modular approach makes the gripper suitable for integration into automated assembly equipment as well as photonics alignment systems.

The gripper provides 500 µm of typical jaw travel and supports opening widths from 0.5 to 1.9 mm, depending on the jaw configuration.

As part of this strategic investment, Oliver Selby has transitioned from his role as Head of Sales to the newly created position of Strategic Key Account Manager – Aerospace & Defence, effective from 1 September 2026. The move represents a major statement of intent from FANUC UK, reflecting the growing importance of the aerospace and defence sectors within the company’s long-term growth strategy. Dan Fisher has been appointed new Head of Sales.

By appointing Oliver, one of its most experienced and influential commercial leaders, to this dedicated aerospace and defence role, FANUC UK is reinforcing its commitment to supporting two of the UK’s most critical manufacturing industries. Oliver will be responsible for developing strategic partnerships with leading aerospace and defence organisations, identifying new opportunities for automation adoption, and helping customers accelerate productivity, resilience and competitiveness through advanced robotics and intelligent automation solutions.

With more than 20 years of experience in robotics and automation, Oliver has been instrumental in helping manufacturers across the UK improve productivity, overcome workforce challenges and successfully implement automation technologies. His appointment reflects FANUC UK’s determination to invest at the highest level in an area that is expected to play a pivotal role in the future of UK manufacturing.

Alongside his position at FANUC UK, Oliver serves as Chair of Automate UK Robotics, where he works closely with industry leaders, policymakers and manufacturers to promote the adoption of robotics and automation across the UK economy. His extensive industry network, deep sector knowledge and proven track record in driving automation-led transformation make him uniquely positioned to lead FANUC UK’s aerospace and defence growth strategy.

Commenting on the appointment, Andy Armstrong, Managing Director of FANUC UK, states: “Aerospace and defence represent a significant long-term growth opportunity for FANUC UK. By appointing Oliver Selby in this dedicated strategic role, we are demonstrating our commitment to investing in the sector and ensuring that our customers have access to the expertise, technology and support needed to succeed in an increasingly competitive global market.”

Oliver Selby adds: “It has been an absolute privilege to lead the sales team at FANUC UK and support the adoption of robots in the UK across a diverse range of industries. The opportunity to focus on aerospace and defence comes at an exciting time, with growing demand for advanced manufacturing technologies across these sectors. I am looking forward to applying my industry experience and expertise to help strengthen FANUC UK’s position in this strategically important market while continuing to support the wider adoption of automation across UK manufacturing.”

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The enhanced offering will make its PPMA debut this September (Stand D90) where, for the first time, visitors to the Endoline stand will see a fully integrated production line combining case erecting, case sealing and palletising.

The demonstration reflects Endoline’s continued commitment to delivering complete, connected end-of-line solutions that can be engineered around each customer’s exact operational needs.

Building on the success of its robotics division, launched in response to growing demand for fully automated packaging systems, Endoline has broadened its robotics portfolio through a collaboration with Montech. The partnership complements the company’s existing robotics capability, enabling Endoline to offer both gantry and articulated robotic solutions as part of its end-of-line automation portfolio.

The expanded capability provides manufacturers with greater flexibility when specifying automation projects. Rather than adopting a one-size-fits-all approach, Endoline can recommend the most appropriate robotic technology based on product type, throughput, factory layout and future production requirements, creating bespoke solutions that evolve alongside each customer’s business.

At PPMA, visitors will see an Endoline Case Erector and case sealer integrated with Montech’s palletising system.

While operating as a complete production line, each machine can also function independently or be integrated into existing packaging operations, providing customers with a scalable approach to automation investment.

“Every production environment is different, which is why we’ve always focused on engineering solutions around our customers rather than expecting customers to adapt to standard equipment,” explains Andrew Yates, Managing Director of Endoline Automation and Endoline Robotics. “Expanding our robotics capability allows us to offer even greater flexibility. Whether a project is best suited to gantry or articulated robotics, our focus remains the same – engineering the right end-of-line solution for that customer’s application.

“As labour availability continues to challenge food manufacturers and demand for automation grows, customers are increasingly looking for complete solutions from a trusted engineering partner. By broadening our robotics offering, we’re able to support a wider range of applications while continuing to deliver the bespoke engineering, reliability and technical support that Endoline has become known for.”

The collaboration also brings together two family-owned engineering businesses with more than 40 years of experience designing automation solutions.

Endoline has successfully integrated its end-of-line systems with Montech technologies on customer installations in Europe for many years, making the latest expansion a natural progression that further strengthens the company’s ability to deliver complete automation solutions for manufacturers in the UK and overseas.

Visitors to stand D90 at the PPMA Show will have the opportunity to discuss bespoke automation projects with Endoline’s engineering team and see how integrated end-of-line systems can be configured to improve productivity, maximise factory space and provide the flexibility needed to support future growth.

Enclosures are designed to enclose robots and other lab-automated processes by providing exhaust air systems or HEPA-filtered clean workstations. Robots are beneficial in many applications and are proven to increase efficiency and productivity. Robots integrated into existing facilities are shown to increase output and improve quality while providing additional flexibility in the production process.

Enclosures are built to protect robotic processes from contamination and personnel from hazardous fumes. Utilising a flexible, modular design, HEMCO enclosures are engineered and built to exact customer size and design requirements.

Christopher’s appointment reflects Endoline’s continued growth and commitment to investing in its engineering capability. He will lead the engineering team while working alongside Trevor King, who has been part of Endoline since its early days in the 1980s.

With more than 40 years’ service, Trevor has played an instrumental role in shaping Endoline’s engineering expertise and reputation for quality. He will continue to support the business, ensuring his extensive technical knowledge and experience remain an integral part of Endoline’s future as the company continues to grow.

Working alongside Endoline’s experienced team of mechanical, electrical and automation engineers, Christopher will oversee the design and development of the company’s end-of-line packaging machinery. His role will focus on driving continuous improvement, supporting new product development and ensuring customers continue to benefit from innovative, reliable engineering solutions.

“What attracted me to Endoline was the opportunity to join a highly specialised engineering business that’s genuinely committed to delivering bespoke solutions for its customers,” said Christopher. “There’s a real sense of pride throughout the company, and every machine is designed with a clear focus on meeting the customer’s specific requirements.

“The complexity behind many of these projects is far greater than people realise, and it’s incredibly rewarding to be part of a team that creates innovative solutions to meet those challenges. It’s also a privilege to be part of a business that champions British manufacturing excellence both here in the UK and internationally.”

For more than 45 years, Endoline has designed and manufactured robust, high-quality end-of-line packaging systems for customers across the food, beverage and consumer goods sectors.

A key strength of the business is its ability to engineer solutions around each customer’s exact operational requirements. Rather than supplying standard equipment, Endoline’s in-house team works closely with customers to understand their production environment, packaging formats and operational challenges before designing automation solutions tailored to their individual needs.

Andrew Yates, managing director of Endoline Automation, said: “Engineering has always been at the heart of Endoline. No two production lines are ever the same, which is why we don’t believe in a one-size-fits-all approach. Our engineers work closely with the sales team and every customer to develop solutions that are tailored to their exact operational requirements, whether that’s adapting an existing machine or creating something completely bespoke.

Christopher’s appointment strengthens that capability and reflects our ongoing commitment to investing in the people and expertise that have underpinned our success for more than four decades.”

Looking ahead, Christopher is focused on supporting the engineering team as the business continues to expand.

He added: “Strong engineering is fundamental to successful automation. Customers invest in automation to improve efficiency and reliability, so it’s essential that every solution is robust, well-designed and fit for purpose. That all starts on the drawing board. My focus is on supporting our talented engineering team, driving continuous improvement and ensuring we continue to bring innovative, high-quality solutions to market as Endoline grows.”

By embedding smart sensing directly into the end-of-arm tooling (EOAT), the project provides real-time grip quality validation, ensuring precision and reliability in highly regulated, fast-moving packaging lines.

In high-speed cosmetics manufacturing, traditional robotic handling systems often struggle with lightweight, flexible components that have tight tolerances, such as deformable thermoformed trays. Whilst industrial robots excel at execution, speed and repeatability, their physical interactions present significant risks. Without tactile feedback, an imbalanced grip can lead to product loss or tray deformation. Traditional validation methods relying on simple position tracking or binary detection offer very little visibility into the actual quality of physical contact, prompting Siléane to seek a measurement-driven alternative to guarantee confidence in every cycle without slowing down the process.

Tactile intelligence at the point of interaction

Rather than increasing system complexity with external inspection steps, Siléane embedded force measurement directly at the point of interaction between the robot and the product. Partnering with HBK, Siléane integrated four factory-calibrated PW22i smart load cells – equipped with IO-Link – directly into the robotic gripper, placing one sensor at each contact point.

This Industry 4.0 setup enables the robot to validate grip quality instantly at the source, capture real-time force data, and respond immediately to any physical deviations during the gripping cycle – whilst simultaneously integrating seamlessly into modern automation architectures.

Simon Kleefeldt, HBK Product Manager Weighing Technology, explains the significance of this development: “This project reflects a fundamental shift in automation: embedding intelligence at the sensor level, to build systems that are more reliable, more autonomous and easier to deploy.”

HBK accelerated the evolution of its proven PW22 load cell – originally designed for demanding, high-speed dynamic weighing applications like checkweighing and filling – into the PW22i by integrating IO-Link connectivity to meet real-world integration demands.

Immediate operational benefits

The integration of the PW22i load cells delivered immediate operational benefits, demonstrating how physical measurement intelligence can improve manufacturing performance. For the end customer, this translates to: zero-defect grip validation in real time across all contact points; significant reductions in product scrap and tray deformation; simplified system architecture with reduced cabling via IO-Link; and faster commissioning times and improved repeatability across installations, ultimately leading to a faster return on investment (ROI).

“Innovation is a core component of Delta’s corporate strategy. We consistently invest more than eight percent of our annual revenue in research and development. Design is a key aspect of this innovation strategy,” said Michael Mayer-Rosa, Senior Director of the Industrial Automation Business Group and Head of Intelligent Robot Systems (IRS) at Delta Electronics, EMEA Region.

“This award validates our team’s high standards in combining industrial robotics with a practical, safe, and efficient design. We are confident that the Delta D-Bot Robots, featuring industry-leading safety, efficiency, and practicality, will meet the demanding needs of our customers across a wide spectrum of applications.”

Delta first unveiled the collaborative robots series to the public in the spring of 2024. The series comprises six highly flexible models, each featuring six axes, payloads of up to 30 kg, and reach capabilities of up to 1,800 mm. The Delta D-Bot series also supports compatibility with OPC UA, PROFINET, EtherCAT, and Modbus TCP, allowing for seamless integration into existing industrial automation environments.

Safety at the core of product design

Collaborative robots are specifically designed to interact with humans within production environments. The “Reflex Safety” technology detects contact in real time and immediately stops robot movement to help prevent accidents and protect both personnel and equipment. The integration of advanced sensing technologies and collision detection capabilities maximise safety.

Furthermore, the Delta D-Bot series complies with IP66 protection standards and supports advanced safety protocols for operation in demanding industrial environments. Its robust design reduces susceptibility to dust and contamination while also simplifying cleaning and maintenance.

Flexible automation for production and logistics

Combined with Delta’s mobile robot platform (MAR – Mobile Autonomous Robot), the Delta D-Bot Collaborative Robot forms the hybrid mobile robotics solution “Delta Dynamic Duo”, a 2-in-1 system that automates flexible transportation and manipulation tasks such as palletising or pick-and-place operations within manufacturing and logistics settings.

The Delta D-Bot series was developed for rapid deployment across a wide range of industrial environments and designed to support diverse applications, including complex component assembly, material handling, and heavy-duty palletising. The collaborative robots combine high precision with efficient automation, helping manufacturers improve productivity and operational flexibility.

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