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.”

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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“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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IQ’s first step is Fit Check, a structured assessment of your operation and your application. Five minutes and then a clear answer: whether palletising is a fit for your floor, what the deployment looks like, and whether the financial return makes sense, including in 1-shift operations.

No site visit. No engineering hours up front. No waiting weeks for a quote that may not go anywhere. Just an honest read on your opportunity, before you commit to anything.

Once the fit is confirmed, IQ powers the full project – built on lessons from over 1,000 Robotiq deployments. It captures the reality of your operation. It connects your team with the right people at the right step. It generates a validated workcell design, simulated in your actual factory environment, so cycle time, reach, payload and all other specs are confirmed.

The result is a deployment-ready palletising workcell with predictable performance from day one. And when you’re ready to add a second line, the same path applies; no custom engineering, no starting from scratch.

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Designed for seamless integration into modern production environments, the new cobots support a wide range of applications, including palletising, machine tending and material handling. Their compact design enables deployment in space-constrained environments, with both external and EDGE integrated controller options supporting mobile and modular setups.

“The introduction of the KR 1824 and KR 1240 marks an important step in expanding the capabilities of collaborative robotics,” said Christoph Rieger, Chief Sales Officer at Kassow Robots. “Our unique combination of EDGE integrated controller, mobile deployment, high payload and extended reach enable more demanding applications within dynamic production environments.”

The new models also deliver improved motion performance, including 50% higher joint torque, more than 20% faster wrist joint speeds, and 40% increased mechanical stiffness. These enhancements enable more stable handling of heavier loads, faster cycle times, and improved precision in demanding applications. Key benefits include:

• Increased payload capacity for more demanding applications
• Seven-axis design for maximum flexibility and extended reach
• Automation of tasks beyond traditional cobot limits
• Compact design and light footprint for space-constrained environments
• Integrated controller option for simplified deployment and mobile integration

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Capable of handling up to 14 bundles of flour per minute across two production lines, the equivalent of between 56 and 168 individual bags of flour every minute, the new system is already playing a key role in supporting increased production volumes and future growth.

Designed to work alongside an existing Endoline palletiser dedicated to one of the site’s two production lines, the upgrade forms part of a broader automation strategy at the facility. The mill operates two filling lines producing both individual 1-2kg bags and larger 18kg shrink-wrapped bundles. The original system, installed five years ago, manages the individual bags from Line 1. This left Line 2’s individual bags, together with the bundles from both lines, requiring a more flexible palletising solution.

Engineered to accommodate both product formats, the system also incorporates the automatic handling and placement of wax paper interlayer sheets. Bundles are conveyed from both lines at speeds of up to 14 per minute per line, equating to a combined throughput of up to 28 bundles per minute. In addition, individual 1-2kg bags from Line 2 are presented at rates of up to 70 bags per minute.

Driving flexibility to support business growth

The replacement project was driven by the need to overcome limitations within the previous palletising operation, which lacked the flexibility to efficiently handle varying bundle sizes and evolving product formats. As the mill expanded its product range and customer requirements for bundle sizes became more diverse, a more adaptable solution was required to support continued growth.

Combining advanced palletising technology with a fully engineered conveyor network, the system enables both bundled flour products and individual packs to flow seamlessly from packing through to pallet build. By automating what were previously labour-intensive and physically demanding tasks, the flour mill has improved operational efficiency, consistency and working conditions across the site.

Integrated palletising and conveyor system

At the heart of the system is a palletising solution capable of managing product streams from the two filling lines. Bundles and individual packs are transferred via a series of accumulation and transfer conveyors, designed to buffer product flow and maintain a continuous feed into the palletising area without disrupting upstream packing operations.

Operating across the two bundling lines, the palletising system can handle up to 14 bundles per minute per line, delivering high-volume throughput while maintaining precise pallet builds and load stability ready for downstream handling and distribution.

While the palletiser can manage the simultaneous pick-up of bundled products from both lines, it requires a straightforward re-tooling process when switching to palletising individual packs of flour, which are fed down the middle conveyor. This quick-change capability allows the mill to move efficiently between product formats in line with production schedules and changing customer requirements.

To minimise downtime during product changeovers, the tooling transition is carried out automatically via the system HMI. The robot docks its current end-of-arm tool, releases it and automatically connects to the alternative tool, ensuring rapid and controlled transitions between bundle and individual pack handling.

Replacing legacy systems with adaptable automation

“Our customer needed a solution that could replace their existing palletising system with something far more adaptable and capable of supporting long-term growth,” comments Suraj Patel, UK Sales Manager, Endoline Robotics. “By integrating high-speed palletising with a tailored conveyor layout, we’ve delivered a flexible operation that can handle different product formats, varying bundle sizes and increasing volumes.”

While enabling the site to move away from manual-intensive tasks, flexibility has been a central design principle throughout the installation. The modular conveyor layout allows for future expansion and capacity increases, while the palletising system can be easily adapted to accommodate new pack sizes, bundle formats and pallet configurations as the business continues to evolve.

“Modern food manufacturers need automation that delivers both performance and adaptability,” Suraj adds. “This project shows how replacing legacy systems with flexible technology can improve efficiency today while providing the capacity to grow tomorrow.”

Building on a long-term partnership

Although the latest installation represents a major upgrade, it builds on an established partnership between the flour milling business and Endoline. In 2020, Endoline delivered a robotic palletising system at the company’s UK-based mill to support a sharp increase in retail demand during the pandemic, enabling production of more than 167,000 bags of flour per week and improving pallet quality and operational continuity.

That earlier project helped shape the company’s wider automation strategy and demonstrated the long-term benefits of palletising technology within the milling environment. With a long-established milling heritage, the business continues to invest in modern manufacturing solutions to remain competitive in a rapidly changing food production landscape.

The palletising and conveyor upgrade reflects this industry trend, providing the flour mill with a future-proof solution that supports current operations while enabling continued growth.

Across Europe and North America, beverage producers, from kombucha and bottled water to major soft drink brands, are standardising cobot palletising to reduce labour strain, control costs, and modernise production.

If palletising is still one of the most manual steps in your production line, you’ll want to hear what triggered the automation decision at Martin Ray Winery, how the installation went, and what the first months of operation looked like.

Register to attend the webinar here

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In the food industry, solutions are in demand that increase efficiency, meet strict hygiene and safety requirements, and enable gentle product transport. Therefore, manufacturers are increasingly investing in modern automation that fulfils these complex requirements.

One solution is the VarioFlow plus – a chain conveyor system from Bosch Rexroth, which, in combination with pre-existing automation and integration from Hitmark Robotics, enables excellent results in palletising, depalletising, and order-picking processes.

The challenges of the food industry – such as variable batch sizes, diverse packaging solutions, and the need for rapid changeovers – require sophisticated solutions for pick-and-place automation. Consequently, more and more companies are opting for comprehensive robotic lines that not only accelerate processes but also ensure their reproducibility and consistently high quality.

This type of implementation is offered by Hitmark Robotics – an integrator of industrial solutions specialising in the automation of end-of-line packaging. The company designs and implements palletising robots, picking stations, depalletising systems and complete transport and control systems. A recent example of this is a production line realised in collaboration with Bosch Rexroth.

Safe transport of demanding products

In the implementation for a dairy producer, the main challenge was to ensure the safe and smooth transport of cartons and crates without damaging them. The VarioFlow plus chain conveyor system, with a system width of 320 mm and a smooth chain surface, is used – ideal for sensitive goods that must be handled with care.

The Rexroth solution consists of: 10 VarioFlow plus chain conveyors with a total length of approximately 57 metres; 10 gear motors; 10 active transfer bridges; and aluminium profile rails with a slide rail for gentle product transport with a wide guide surface.

The cardboard boxes are delivered directly to the line from the packaging machines, lifted vertically, and transported at a height of approximately 2.5 metres. This system layout allows for continuous production while simultaneously leaving free space underneath the system, which is used for both employee traffic and for operating transport carts.

Robot palletising – precision that pays off

At the end of the line, there are stations that prepare packages for collection by the palletising robot. Here, the system automatically separates the products and arranges them according to a defined pattern. Thanks to the integration with the automation system developed by Hitmark, it is not only possible to smoothly connect the line to the robot but also to continuously monitor operating parameters and quickly reconfigure in case of packaging or format changes.

Bosch Rexroth supplied a highly developed transport system; Hitmark Robotics handled its integration, automation configuration and connection to the palletising system. Both companies share a common vision: to create solutions that function reliably, flexibly and scalably, even in the most demanding industries. Key benefits of the implementation included:

• Minimised risk of damage to transported goods
• Optimal use of space
• Consistent performance
• Ability for rapid expansion or reconfiguration
• Automatic preparation of packages for palletising
• Reliable operation even under difficult production conditions

The future of automation

Modern automation must be forward-thinking, consider the actual needs of the facility, allow for flexibility, and at the same time enable safe processes.

The combination of Hitmark Robotics’ expertise and Bosch Rexroth’s reliable products, such as the VarioFlow plus chain conveyor system, provides an optimal solution. And if palletising, mixing, or transporting food and its packaging becomes a bottleneck in your company, it is worth exploring which solution is right for you.

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The TM30S, TM20S and TM6S extend the series’ payload and reach capabilities for applications such as palletising, machine tending and precision handling.

• TM30S: 30 kg payload model designed for heavy-duty collaborative tasks including palletising and machine tending.
• TM20S: 20 kg payload unit offering extended reach for mid-to-high payload operations.
• TM6S: Long-reach 6 kg payload model optimised for precision handling, welding support and mobile robot integration.

Across the S Series, OMRON has introduced upgrades to increase durability and support faster redeployment. All robot arms now feature an IP65 rating for use in washdown or dust-prone environments. Higher-payload units (TM25S, TM30S) incorporate an integrated joint 6 force-torque wrist sensor for improved force-controlled processes. The updated Landmark 2.0 vision-based positioning system is designed to reduce recalibration time when moving robots between stations.

TMflow 2.22 software release

OMRON has also released TMflow 2.22, an update to its no-code programming environment. The new version introduces more granular safety configuration options, expanded remote monitoring and diagnostics and a higher-fidelity simulation engine. Integrated vision tools have been strengthened to support inspection and pick-and-place tasks with greater accuracy.

“By introducing the TM30S, TM20S, and TM6S alongside crucial upgrades like IP65 certification and the integrated joint 6 force torque sensor, we are empowering our customers to automate their most challenging, heavy-duty tasks with greater safety, precision, and flexibility than ever before,” said Qiqi Wang, Global Product Manager at OMRON Robotics and Safety Technologies. “TMflow 2.22 ensures that this immense power remains easy to program and manage, upholding our commitment to harmonious automation.”

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Palletising is a repetitive and strenuous task that poses risk of injury to workers. For manufacturers looking to increase efficiency, palletising is an easy choice in terms of tasks to automate. Implementing a robotic solution to take the strain of repetitive palletising tasks increases safety for workers and allows staff to be re-allocated to more rewarding, higher-value tasks.

Robotiq offers a choice of two different approaches to easy, simple palletising automation: PAL Ready and PAL Series. PAL Ready is a production-ready palletiser which utilises the UR20 model from Universal Robots. The solution includes everything manufacturers need to get started and is designed for rapid installs. A vacuum gripper, a mobility kit (which allows the cell to be moved to different lines), a safety package and a smart infeed roller conveyor are all included in the PAL Ready package.

PAL Series, on the other hand, is a modular approach based on standard Robotiq components. This option offers a choice of five different palletiser models, along with optional extras such as grippers, safety packages, mobility kits, interlayer racks and more. Users can choose to add or remove these components to suit their application needs.

RARUK Automation is a Robotiq Expert Partner and was named Universal Robots’ Top Global Distributor in 2024. With previous deployments, Robotiq Palletising Solutions have proven popular due to their small footprint, making it easy to fit them into existing production lines. The PE10 has a payload capacity of 11.5 kg (25 lb) and a stacking height of 1,550 mm (60 in). The solution offers a cycle time of 13 cycles/ min.

Designed to enhance efficiency, Robotiq’s easy-to-use software makes it quick and simple to get a robotic palletising solution up and running. Staff can effortlessly adapt production through an intuitive interface. With Robotiq’s Multi-recipe feature, it is easy to accommodate product changeovers.

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