Flex Stack Pro | CODI Manufacturing
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Introducing

Flex Stack Pro

The Flex Stack Pro is the high-performance model in the Flex Stack line, it is a highly configurable system. As shown, it features a dual-pallet system that enables simultaneous loading and discharge for uninterrupted operation and maximum throughput. It combines the flexibility and cost advantage of cobots with the speed, reliability, and durability of industrial gantries—all in a compact, operator-friendly design that’s easy to maintain and delivers consistent ROI across industries from craft beverages to logistics and consumer goods

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Built on the Festo FPaKit and easily configured, the Flex Stack Pro ships as a pre-engineered, largely assembled solution—reducing installation time onsite while ensuring perfectly matched components. Backed by Festo’s global support network and equipped with monitoring and predictive analytics, it not only automates palletizing but also future-proofs operations. With advanced safety features, mobile redeployment, and intuitive software for pallet pattern setup, the Flex Stack Pro minimizes downtime, lowers total cost of ownership, and keeps production running smoothly.
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​FEATURES

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  • Modular gantry-based design powered by Festo Handling Guide Online (HGO) and Festo’s FPaKit.​

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  • Two models: Flex Stack:

    • Single-pallet system, compact footprint, cost-effective for lower throughput needs.

    • Flex Stack Pro: Dual-pallet system enabling one pallet to be discharged while the other is loaded, maximizing throughput.

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  • Fully assembled kits from Festo: Motors, drives, axes, grippers, pneumatics, and pre-loaded PLC software arrive preconfigured, requiring minimal setup.

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  • Flexible power and integration: Runs on 120V, 220V, or 480V; adaptable to customer plant standards.

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  • Compact footprint: Occupies little more than the pallet size itself, saving floor space versus robotic arms or manual palletizing.

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  • Advanced safety: Full enclosure with guarding and light curtains.

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  • Monitoring and predictive analytics: Integration of Festo AX Motion Insights and pneumatic/electric monitoring tools provides real-time performance baselines and failure prediction. Customizable grippers: Suction cups and rotary heads spec’d by Festo, with CODI providing custom brackets.

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  • HMI and intuitive software: Easy setup of pallet patterns and product configurations.

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  • Mobility: Skid-based design allows relocation by pallet jack or forklift.

​BENEFITS

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  • Engineering and assembly savings: Estimated 20–30 hours saved in engineering and 10–15 hours saved in assembly per unit.

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  • Optimized system sizing: HGO ensures motors, drives, and axes are correctly specified, eliminating risk of over/undersizing.

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  • Cost advantage: Competes directly with cobots—similar flexibility but faster, more reliable, and less expensive (~$100K target price).

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  • Simplified maintenance: Gantry system is easier for in-house mechanics to service versus complex robot gearboxes.

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  • Improved uptime: Predictive analytics allow planned maintenance and reduced spare-parts inventory while minimizing downtime.

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  • Better ergonomics & safety: Removes repetitive and injury-prone manual palletizing tasks.

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  • Broad application: Effective for beverage, food, 3PL variety packs, consumer goods, and internal manufacturing logistics.

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  • Scalable ROI: Designed for rapid payback—often one year—by reducing labor and increasing throughput.

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  • Future-ready: Can integrate tier sheet placement and other enhancements.

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