{"id":6368,"date":"2026-05-15T15:31:51","date_gmt":"2026-05-15T06:31:51","guid":{"rendered":"urn:uuid:89bd6f48-650e-4515-88ec-bebe2555e494"},"modified":"2026-05-15T15:32:34","modified_gmt":"2026-05-15T06:32:34","slug":"high-throughput-robotic-palletizing-delivers-measurable-gains-in-productivity-safety-and-roi","status":"publish","type":"case_study","link":"https:\/\/kawasakirobotics.com\/in\/case-studies\/high-throughput-robotic-palletizing-delivers-measurable-gains-in-productivity-safety-and-roi\/","title":{"rendered":"High-Throughput Robotic Palletizing Delivers Measurable Gains in Productivity, Safety, and ROI"},"content":{"rendered":"\n

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.<\/p>\n\n\n\n

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:<\/p>\n\n\n\n

\n

We don\u2019t just replace equipment. We look at the entire process and ask how to make it better for the long term.<\/p>\n<\/blockquote>\n\n\n\n

Project Challenge<\/strong><\/h2>\n\n\n\n

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:<\/p>\n\n\n\n

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

    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.<\/p>\n\n\n\n

    Doug McGuire, Segment Lead & Sales Engineer at SCADAware, noted:<\/p>\n\n\n\n

    \n

    The robot was doing too much. That gap between finishing one pallet and starting the next, about 75 seconds, was the biggest hidden loss.<\/p>\n<\/blockquote>\n\n\n\n

    Project Solution<\/strong><\/h2>\n\n\n\n

    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.<\/p>\n\n\n\n

    Key System Enhancements Included:<\/strong><\/p>\n\n\n\n

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

      This approach reduced the robot\u2019s task burden and dramatically shortened the transition time between pallets. Scott Dappen, VP of Engineering at SCADAware, emphasized the value of the partnership:<\/p>\n\n\n\n

      \n

      We leverage our internal expertise and combine it with technology partners like Kawasaki Robotics to deliver the best possible solution for each customer.<\/p>\n<\/blockquote>\n\n\n\n

      \n
      \"\"<\/figure>\n\n\n\n
      \"\"<\/figure>\n\n\n\n
      \"\"<\/figure>\n\n\n\n
      \"\"<\/figure>\n<\/figure>\n\n\n\n

      Results<\/strong><\/h2>\n\n\n\n

      The redesigned palletizing system delivered immediate, measurable performance improvements.<\/p>\n\n\n\n

      Quantifiable KPIs & Operational Gains<\/strong><\/p>\n\n\n\n

      Metric<\/strong><\/td>Before<\/strong><\/td>After<\/strong><\/td><\/tr>
      Time per pallet<\/strong><\/td>825 seconds<\/td>770 seconds<\/td><\/tr>
      Time between pallets<\/strong><\/td>75 seconds<\/td>20 seconds<\/td><\/tr>
      Annual pallet output<\/strong><\/td>38,225 pallets<\/td>40,956 pallets<\/td><\/tr>
      Throughput improvement<\/strong><\/td>\u2014<\/td>+7% annually<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

      This equates to approximately 2,700 additional pallets per year, translating into ~$1.5 million in incremental annual revenue, based on the customer\u2019s product value estimates.<\/p>\n\n\n\n

      Additional Value Delivered<\/strong><\/p>\n\n\n\n

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

        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.<\/p>\n\n\n\n

        As McGuire explained:<\/p>\n\n\n\n

        \n

        When they saw the throughput increase and how quickly it paid for itself, the decision was easy.<\/p>\n<\/blockquote>\n\n\n\n

        Summary<\/strong><\/h2>\n\n\n\n

        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:<\/p>\n\n\n\n

          \n
        • Increased throughput<\/li>\n\n\n\n
        • Reduced downtime<\/li>\n\n\n\n
        • Improved safety<\/li>\n\n\n\n
        • Delivered compelling ROI<\/li>\n<\/ul>\n\n\n\n

          Rick Caldwell summarized the philosophy behind the success:<\/p>\n\n\n\n

          \n

          \u201cWe build systems with honesty, integrity, and a long-term focus. That\u2019s how you stay in business for over 25 years\u2014and how you build partnerships that last.\u201d<\/p>\n<\/blockquote>\n\n\n\n

          <\/p>\n","protected":false},"excerpt":{"rendered":"

          SCADAware Inc. partnered with Kawasaki Robotics to transform an aging, labor-intensive palletizing o […]<\/p>\n","protected":false},"author":22,"featured_media":6372,"template":"","objective":[],"class_list":["post-6368","case_study","type-case_study","status-publish","has-post-thumbnail","hentry"],"yoast_head":"\nHigh-Throughput Robotic Palletizing Delivers Measurable Gains in Productivity, Safety, and ROI | Industrial Robots by Kawasaki Robotics<\/title>\n<meta name=\"description\" content=\"Kawasaki Heavy Industries | High-Throughput Robotic Palletizing Delivers Measurable Gains in Productivity, Safety, and ROI\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/kawasakirobotics.com\/in\/case-studies\/high-throughput-robotic-palletizing-delivers-measurable-gains-in-productivity-safety-and-roi\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta 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