Flex Stack
FLEX STACK: Cartesian Gantry Palletizer
Automated gantry palletizer and depalletizer | End-of-line material handling for CPG, industrial, and co-packing facilities
The CODI Flex Stack Pro is a compact Cartesian gantry palletizer and depalletizer that handles payloads up to 110 lbs (50 kg) per pick across single, dual, or triple bay pallet stations. It is engineered for high-throughput material handling in space-constrained facilities and designed to outperform collaborative robots. Browser-based HMI controls let your team adjust layer patterns and case dimensions with ease. Paired with case packers and cartoners, it provides complete end-of-line automation for CPG, industrial manufacturing, co-packing, and food processing operations.
The CODI Flex Stack Pro is a compact Cartesian gantry palletizer and depalletizer that handles payloads up to 110 lbs (50 kg) per pick across single, dual, or triple bay pallet stations. It is engineered for high-throughput material handling in space-constrained facilities and designed to outperform collaborative robots. Browser-based HMI controls let your team adjust layer patterns and case dimensions with ease. Paired with case packers and cartoners, it provides complete end-of-line automation for CPG, industrial manufacturing, co-packing, and food processing operations.
PRODUCT FEATURES
Flex Stack Payload & Weight Capacity
At up to 110 lbs per pick, the Flex Stack Pro handles loads that collaborative robots can't. Heavier cases, faster builds, more stable stacks.
Browser-Based Pattern Programming
No external programmer needed. Your team adjusts case dimensions, stack patterns, and pallet configurations through any standard web browser, with automatic pattern generation and 3D visualization built in.
Simple Gantry Mechanics
Cartesian linear axes have fewer wear points than multi-axis robots. That means more reliable uptime and maintenance your own team can actually manage.
Dual-Pallet Continuous Operation
A dual-pallet configuration keeps the system running while one pallet is swapped out. No stopping the line to reload.
PRODUCT INFORMATION
Compact Design: slightly wider than a pallet
Variety Packs
More efficient that cobots
Flex Stack Payload & Weight Capacity
Up to 44 lb (20 kg) – Light weight
Up to 66 lb (30 kg) – Normal Duty
Up to 110 lb (50 kg) – Heavy
Payload includes product, packaging, and end-of-arm tooling
Throughput
Up to 4–15 cases per minute (Actual rate depends on case size, layer pattern, and pallet configuration)
Pallet Configurations
Single-pallet
Dual-pallet (continuous operation)
Twin-pallet discharge/load capability
Mixed pallets supported
Motion Platform
Cartesian / gantry architecture
Servo-driven linear axes
Z-axis with integrated brake
Controls & Interface
Browser-based HMI (Chrome, Edge, Firefox)
No programming required
Automatic pallet pattern generation
3D pallet visualization and validation
End-of-Arm Tooling
Vacuum-based case handling
Integrated vacuum sensing
Tier sheet capability (optional)
Utilities
Pneumatics: Required for vacuum systems
Controls: Industrial Ethernet / multiprotocol architecture
Safety
High-speed operation with perimeter guarding
Safety design tailored to line layout and risk assessment
System Footprint & Line Integration
Compact, application-specific layout
Typically smaller than comparable cobot palletizing cells
Mounting
Skid-mounted
Forklift or pallet-jack movable
Certification
UL
CSA Compliant
CE Compliant
Voltage
100-240V / 1PH
208-240V / 1PH
208-240V / 3PH
380-500V / 3PH
100-240V / 1PH
208-240V / 1PH
208-240V / 3PH
380-500V / 3PH
Controls Platform
Festo
ABI
Box Type & Weight
Specify
Kg Of Gantry
Light
Normal
Heavy
Power Coat Color
Specify
Skid Mounted
Y/N
Configuration
Case Un-Packer
Case Packer
Both Case Packer & Un-Packer
Product Size
Specify
Speed (Desired Carton Per Minute)
5 - 15
Frame Construction
Carbon Steel
Stainless Steel
Vision (SICK)
Y/N
High Payload Capacity
Handles heavier loads than collaborative robots (cobots) for faster, more stable palletizing.
Payload options up to 110 lb (50 kg) including product and tooling
Supports light, standard, and heavy-duty configurations
Enables higher throughput and improved pallet stability
Throughput & Performance
Designed for consistent case handling across a range of palletizing applications.
Up to 4–15 cases per minute depending on configuration
Maintains repeatable cycle times across varying loads
Supports continuous, high-efficiency operation
Gantry Motion System
Cartesian architecture provides durability, precision, and long-term reliability.
Servo-driven linear axes for accurate positioning
Fewer wear components compared to articulated robots
Z-axis with integrated brake for controlled vertical movement
Automation & Controls
Simplifies operation with intuitive, browser-based control and automated setup.
Browser-based HMI accessible via Chrome, Edge, or Firefox
No programming required for operation
Automatic pallet pattern generation with real-time 3D visualization
Flexible Palletizing Configurations
Adapts to changing production needs and multiple pallet formats.
Supports palletizing, depalletizing, and mixed pallet builds
Single and dual-pallet configurations available
Designed for future production changes without major rework
End-of-Arm Tooling
Configurable tooling supports a wide range of case handling requirements.
Vacuum-based case handling system
Integrated vacuum sensing for secure picks
Optional tier sheet handling capability
Line Integration
Designed to integrate into existing packaging lines with minimal disruption.
Skid-mounted system for simplified installation and relocation
Compact footprint compared to robotic palletizing cells
Compatible with upstream case packing and downstream pallet handling
Construction & Components
Built with globally supported components for long-term serviceability.
Festo-powered motion, drives, and vacuum technology
Industrial-grade mechanical design for continuous operation
Configurable frame construction (carbon steel or stainless)
Labor Reduction & ROI
Replaces manual palletizing with a repeatable, efficient system.
Reduces labor dependency and variability
Improves pallet consistency and load integrity
Fast return on investment through increased uptime and output
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FAQ
How does a gantry palletizer compare with a collaborative robot (cobot)?
A Cartesian gantry, like the Flex Stack Pro, runs servo-driven linear axes inside a compact frame, holding 4 to 15 cases per minute continuously. It keeps the configurability of a cobot but runs at industrial gantry speeds at a much more accessible price and smaller footprint.
What payload can the Flex Stack handle?
The system handles payloads across three tiers: up to 44 lbs (light duty), 66 lbs (normal duty), and 110 lbs (heavy duty). This payload includes the product, its packaging, and the end-of-arm tooling.
Does a new pallet pattern require a controls engineer to operate?
No. The HMI is browser-based. Pallet patterns generate automatically and are validated against a 3D visualization before the system runs them, requiring zero outside programming.
Can it run continuously without stopping for pallet changes?
Yes. The dual-pallet configuration loads one pallet while discharging the other. Feeding it directly from the Flex Pack cartoner keeps case handling 100% automated from packing through final palletizing.
