Flex Stack Pro
Robotic Gantry
Palletizer/Depalletizer
The Flex Stack Pro automates case palletizing and depalletizing using a compact gantry design that fits where floor space is limited and labor is tight. With payload capacity up to 110 lbs—well beyond similarly sized collaborative robots—the system handles 4–15 cases per minute, depending on configuration.
Built on a modular platform, Flex Stack Pro supports multiple control options and uses browser-based pallet pattern programming, so operators can make changes without specialized coding or outside support. Dual-pallet configurations allow for continuous operation, while simple linear mechanics keep maintenance predictable and downtime low compared to multi-axis robots.
The result is fewer manual lifts, improved ergonomic safety, and consistent, repeatable pallet quality—shift after shift. That’s why palletizing gantry robots are trusted across food and beverage, consumer packaged goods, co-packing, logistics, industrial manufacturing, building materials, agriculture, and pharmaceutical secondary packaging—and why many facilities move to gantry automation sooner than planned once labor and throughput constraints become unavoidable.
Flex Stack Features
Engineered For Adaptability
Configured to Your Needs:
Available in Single, Dual, or Triple Bay pallet stations to match your upstream machine speed. Powercoat painted to any color you specify.
Universal End-of-Arm Tooling (EOAT):
Vacuum, gripper, or clamp? We configure the EOAT based on your case weight and top surface material, ensuring secure handling for even the most delicate or heavy SKUs.
Future-Proof Pattern Programming:
High SKU turnover? The browser-based interface allows your internal leads to adjust case dimensions and stack patterns without expensive external programming support.
Small Footprint:
The compact gantry architecture designed for facilities with limited approximate floor space.
Flex Stack systems are engineered to each application. Specifications vary based on product, pallet pattern, throughput, and facility constraints.
Baseline Specifications (Application-Dependent)
Payload Capacity
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Up to 44 lb (20 kg) – Light weight
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Up to 66 lb (30 kg) – Normal Duty
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Up to 110 lb (50 kg) – Heavy
Payload includes product, packaging, and end-of-arm tooling
Throughput
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Up to 4–10 cases per minute (Actual rate depends on case size, layer pattern, and pallet configuration)
Pallet Configurations
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Single-pallet
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Dual-pallet (continuous operation)
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Twin-pallet discharge/load capability
Mixed pallets supported
Motion Platform
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Cartesian / gantry architecture
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Servo-driven linear axes
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Z-axis with integrated brake
Controls & Interface
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Browser-based HMI (Chrome, Edge, Firefox)
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No programming required
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Automatic pallet pattern generation
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3D pallet visualization and validation
End-of-Arm Tooling
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Vacuum-based case handling
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Integrated vacuum sensing
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Tier sheet capability (optional)
Utilities
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Electrical: Application-specific
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Pneumatics: Required for vacuum systems
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Controls: Industrial Ethernet / multiprotocol architecture
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Safety
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Traditional industrial safety architecture
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High-speed operation with perimeter guarding
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Safety design tailored to line layout and risk assessment
Footprint
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Compact, application-specific layout
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Typically smaller than comparable cobot palletizing cells
Mounting
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Skid-mounted
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Forklift or pallet-jack movable
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Higher Payloads Than Cobots
Handles significantly heavier loads than collaborative robots, enabling faster pallet builds and more stable stacks.
Configurable for Palletizing or Depalletizing
Adaptable for palletizing, depalletizing, mixed pallets, and future production changes.
Simple Linear Gantry Mechanics
Robust Cartesian design minimizes wear points, improves reliability, and reduces long-term maintenance costs.
Browser-Based Operator Interface
No programming required. Operators configure patterns and parameters through any standard web browser.
Automatic Pattern Generation & 3D Visualization
One-click pallet pattern creation with real-time 3D visualization, rotation, and validation checks.
Festo-Powered Mechatronics
Built on globally supported Festo servo drives, motors, motion control, and vacuum technology for long-term serviceability.
Expandable & Scalable Platform
Designed to grow with production—add capacity, configurations, or automation without replacing the machine.
Fast ROI vs. Manual Labor
Engineered to reduce labor dependency, improve pallet integrity, and deliver payback in as little as one year. Eliminate the "impact of no-shows" on your daily output. Competitive pricing combined with high durability ensures ROI/Payback alignment typically within [Insert Months] months.
Safety First
Removes operators from repetitive, injury-prone tasks, directly improving your facility's OSHA/Ergo history.
Easy Integration
Compatible with various upstream machine types (fillers, packers, labelers).
