Flexible robot palletizing

With a flexible and scalable robot palletizing solution, FK Distribution has achieved high uptime, increased capacity, and a future-proof production setup—developed and implemented in close collaboration with Eltronic.

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Flexible robot palletizing ensures high operational reliability and scalability

99% uptime. Scaled from one to eight robot cells. Ready for further growth.

FK Distribution A/S handles large volumes of advertising bundles every day, where even short production stops can have significant consequences. Efficient operations, high uptime, and optimal space utilization are therefore not just important parameters—they are business-critical.

When an older mechanical palletizing system began to impose clear limitations on both capacity and flexibility, it became evident that the production setup needed to be rethought. Together with Eltronic, FK Distribution took the step towards a robot-based palletizing solution that has since transformed a key part of their production.

The result is a compact, reliable, and scalable setup, now implemented across nine installations and easily expandable as demand grows. A solution that has not only significantly increased capacity but also ensured stable and future-proof operations.

Challenge

Aging mechanical palletizing system with limited capacity
High risk of breakdowns and production stops
Large footprint in production
Limited flexibility with varying product sizes and packaging types
Direct impact on delivery performance during downtime

Solution

Robot-based palletizing solution
Prototype project as the foundation for scaling across installations
Custom-designed gripper for varying advertising bundles
Standardized palletizing logic for consistent operations
Flexible handling of both metal cages and cardboard boxes

Results

Uptime increased from approx. 90% to 99%
Significantly higher capacity and stable operations
Up to 10% improved pallet fill rate
Reduced space requirements with a compact robot cell
Scalable solution implemented across nine installations

FK Distribution shares their experience

“For us, it has been fantastic to have a single point of contact from project start to completion. I would definitely recommend working with Eltronic. The outcome of the project has been outstanding—it reflects quality from start to finish, and overall, it has been a great project.”

Jan Pedersen, Technical Manager, FK Distribution.

When requirements for palletizing changed

FK Distribution’s previous palletizing system was more than 20 years old and based on mechanical technology. It required significant space, had limited capacity, and was vulnerable to breakdowns. In the event of downtime, trucks could end up waiting in the yard, directly impacting delivery performance.

At the same time, product sizes varied continuously, placing demands on a level of flexibility that standard solutions could not provide. FK Distribution needed a robust and future-proof solution that could handle changing requirements, improve daily operations, and enable easy scalability.

A flexible and scalable robot solution

The solution was a robot-based palletizing system developed and implemented in close collaboration between FK Distribution and Eltronic. The project began with a prototype setup using a single robot to test the solution in practice.

“We started with a prototype project using one robot. Afterwards, we purchased seven more – and we’ve just bought another one. That pretty much says it all.”

Jan Pedersen, Technical Manager, FK Distribution

For FK Distribution, it was essential to implement a palletizing solution capable of handling significant variations in both products and packaging types without compromising operational reliability. To achieve this, a specially designed gripper tool was developed, enabling the robots to safely and consistently handle advertising bundles of varying sizes and materials.

The result is a highly flexible solution in which the robot cells can handle both metal cages and cardboard boxes without changes to the setup. This provides FK Distribution with a robust and future-proof production environment that can easily adapt to changes in materials and deliveries – without downtime or manual reconfiguration.

At the same time, the palletizing logic was standardized, allowing the solution to be easily scaled and implemented across multiple sites. This ensures consistent operations and makes it possible to rapidly expand capacity as needs evolve.

Results that make a difference in daily operations

Today, the robot solution has been implemented across eight facilities, ensuring consistent operations throughout the production setup. This has resulted in significantly improved uptime, increased capacity, and better utilization of pallets.

The compact robot cell has reduced the space required in production, while the enhanced flexibility allows operations to quickly adapt to changes in both packaging and product formats. Overall, the solution has provided FK Distribution with a more robust and future-proof production setup, characterized by high reliability and easy scalability.

“One of the biggest limitations before was that the system could only produce cages. With robots, there is a completely different level of flexibility.”

Anders Bjerrisgaard Frydensbjerg, Logistics Director, FK Distribution

A partnership throughout the entire journey

A key factor in the success of the project has been the close and trust-based collaboration between FK Distribution and Eltronic. FK Distribution highlights the value of having a single partner throughout the entire process – from initial concept to commissioning.

“For us, it has been fantastic to have one point of contact from project start to finish. I would definitely recommend working with Eltronic. The outcome of the project has been outstanding – it reflects quality from start to finish, and overall it has been a fantastic project.”

Jan Pedersen, Technical Manager, FK Distribution

The collaboration has resulted in a solution that meets both technical and operational requirements, as well as a partnership built on years of trust and proven results.

See the solution in action

See how the robot palletizing solution works in practice at FK Distribution, and how high uptime, flexibility, and scalability have become an integral part of daily operations.

Ready to take the next step?

Contact us to learn how we can help you with a flexible and reliable automation solution.

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Eltronic A/S

Eltronic A/S is an ambitious engineering company with more than 25 years of experience developing production systems and automation. Our goal is to be our customers’ preferred partner and to increase their global competitiveness and sustainability.

Contact us

Eltronic A/S, Hedensted
Kilde Allé 6
DK-8722 Hedensted

Eltronic A/S, Ballerup
Brydehusvej 30
DK-2750 Ballerup

Eltronic A/S, Hillerød
Slotsgade 13-17
DK-3400 Hillerød

Eltronic A/S, Odense
Forskerparken 10
DK-5230 Odense M

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