SCADAware Inc. partnered with Kawasaki Robotics to transform an aging, labor-intensive palletizing operation into a high-performance, data-driven robotic cell designed for long-term operational value.

What began as a request to simply replace an end-of-life robot quickly evolved into a comprehensive automation solution that addressed throughput constraints, safety risks, downtime, and future scalability. By re-engineering the entire palletizing cell, not just the robot, SCADAware delivered a system that significantly increased production capacity while reducing operational strain on personnel. As Rick Caldwell, President of SCADAware Inc., explains:

We don’t just replace equipment. We look at the entire process and ask how to make it better for the long term.

Project Challenge

The customer operates a 24/7 palletizing line that stacks 50-lb bags onto pallets at high volume. Under ideal conditions, the existing system required:

• 825 seconds per pallet
• 75 seconds of idle time between completed pallets
• Manual pallet loading and frequent lock-out/tag-out (LOTO) interruptions
• An aging robot prone to breakdowns, forcing manual palletizing during downtime

Even at peak performance, the operation was capped at approximately 38,225 pallets per year. That figure did not account for real-world downtime caused by pallet replenishment, maintenance, or safety stoppages. Most critically, the robot was overloaded with non-value-added tasks retrieving pallets and slip sheets creating inefficiencies that a simple robot replacement could not solve.

Doug McGuire, Segment Lead & Sales Engineer at SCADAware, noted:

The robot was doing too much. That gap between finishing one pallet and starting the next, about 75 seconds, was the biggest hidden loss.

Project Solution

SCADAware proposed a holistic cell redesign anchored by a new Kawasaki CP180L palletizing robot, supported by strategically selected automation components that removed unnecessary workload from the robot and eliminated production stoppages.

Key System Enhancements Included:

• Kawasaki CP180L palletizing robot selected for payload capacity, availability, and reliability
• Continuous-load pallet dispenser enabling production without stopping the cell
• Automated bottom slip-sheet applicator, eliminating robot-handled pallet prep
• Improved cell access and safety architecture, including Fortress interlocks and a streamlined LOTO process
• Integrated PLC and SCADA data access, allowing operators and managers to monitor:
• Cell status
• Downtime reasons
• Reject data
• Production throughput

This approach reduced the robot’s task burden and dramatically shortened the transition time between pallets. Scott Dappen, VP of Engineering at SCADAware, emphasized the value of the partnership:

We leverage our internal expertise and combine it with technology partners like Kawasaki Robotics to deliver the best possible solution for each customer.

Results

The redesigned palletizing system delivered immediate, measurable performance improvements.

Quantifiable KPIs & Operational Gains

Metric	Before	After
Time per pallet	825 seconds	770 seconds
Time between pallets	75 seconds	20 seconds
Annual pallet output	38,225 pallets	40,956 pallets
Throughput improvement	—	+7% annually

This equates to approximately 2,700 additional pallets per year, translating into ~$1.5 million in incremental annual revenue, based on the customer’s product value estimates.

Additional Value Delivered

• Reduced unplanned downtime due to improved robot reliability
• Improved ergonomics and worker safety by eliminating manual palletizing
• Faster and safer cell entry for maintenance and replenishment
• Real-time production visibility through integrated data reporting

Notably, during the quoting phase, the customer chose the higher-investment solution without prolonged deliberation recognizing the long-term ROI and operational resilience it delivered.

As McGuire explained:

When they saw the throughput increase and how quickly it paid for itself, the decision was easy.

Summary

This project exemplifies how SCADAware Inc. approaches automation not as a one-for-one equipment swap, but as a strategic investment in performance, safety, and scalability. By combining deep process understanding, data-driven decision-making, and a trusted partnership with Kawasaki Robotics, SCADAware delivered a future-ready palletizing system that:

• Increased throughput
• Reduced downtime
• Improved safety
• Delivered compelling ROI

Rick Caldwell summarized the philosophy behind the success:

“We build systems with honesty, integrity, and a long-term focus. That’s how you stay in business for over 25 years—and how you build partnerships that last.”