Marketplace
Palletizing as the next automation step at
DEUTZ AG
Palletizing in a highly automated logistics center
An automated palletizing solution was implemented at the DEUTZ AG logistics center in Cologne to further reduce manual processes and make material flow more efficient. Unchained Robotics realized the palletizing solution as a turnkey system and integrated it into DEUTZ's existing logistics environment. A MalocherBot Palletizer S is used, equipped with a Doosan P3020 cobot and a custom-developed gripper that handles the palletizing of KLT containers and integrates seamlessly into the existing, highly automated logistics environment.
The system is designed to work optimally with DEUTZ's existing autonomous mobile robots (AMRs). These take over the transport of pallets within the logistics center, while the MalocherBot performs palletizing reliably and reproducibly. This creates a continuous, automated process from goods transport to the palletized unit.
Customer Profile DEUTZ AG
DEUTZ AG is a globally operating manufacturer of drive systems based in Cologne. The company was founded in 1864 and is one of the most traditional engine manufacturers in the world. DEUTZ develops and produces powerful and efficient drive solutions for applications in construction, agriculture, material handling, and other industrial sectors.
As a technologically leading company, DEUTZ has relied on a high degree of automation in production and logistics for many years. Modern manufacturing and logistics concepts, digital processes, and the use of autonomous transport systems are central components of the corporate strategy to sustainably secure efficiency, quality, and competitiveness.
Customer
DEUTZ AG, Cologne, Germany
Application
Palletizing KLT containers in a highly automated logistics center
Software
LUNA Automation Operating System
Hardware
MalocherBot Palletizer S, Doosan P3020 Cobot, custom-developed gripper, light curtains
System Integration
Unchained Robotics
Commissioning
2025
Result
Automated and reliable palletizing of KLT containers, reduced manual work, and seamless integration into the existing logistics environment including AMRs
We are absolutely satisfied with the final product. The solution fits very well with our process and fulfills exactly what we expected from it. It was particularly important for us that all electrical and mechanical interfaces – including those to the conveyor technology and our AGVs – were cleanly implemented. The small space requirement of the cell also convinced us.
Christoph Heid
Head of Technology, Systems and Maintenance, Logistics Center
Challenge Efficiently automating the last process step
DEUTZ pursued the goal of further optimizing existing logistics processes and unlocking additional efficiency potentials. In particular, palletizing was to be more strongly automated to reduce manual activities and ensure uniform, plannable material flow.
In an already highly automated environment, the challenge was to integrate a solution that flexibly fits into existing processes and consistently automates another previously manual process step. The goal was to represent empty container handling as the last building block in a comprehensive automation strategy in a stable, efficient, and future-proof manner. Efficiency improvement, process stability, and future security were clearly the focus.
Solution Palletizing with MalocherBot Palletizer S
A MalocherBot Palletizer S was implemented, designed as a compact and powerful palletizing cell for use in the logistics center. The system is equipped with a Doosan P3020 cobot and uses a custom-developed gripper for safe handling of KLT containers. The use of light curtains ensures simple and safe access for operators at all times.
The solution takes over the automatic palletizing of KLT containers and integrates smoothly into the existing logistics infrastructure. It complements the already existing automation components and closes a previously manual process gap in empty container handling. Due to the open safety architecture and compact design, the cell is particularly suitable for dynamic logistics environments with frequent process adjustments.
Why this solution is ideal for logistics centers
Automated palletizing systems like the MalocherBot Palletizer S enable a significant increase in efficiency and process stability in logistics operations. The combination of collaborative Doosan P3020 robot and custom gripper allows precise and gentle palletizing of KLT containers. They ensure consistent quality, reduce manual interventions, and create the foundation for a continuously automated material flow.
Especially in highly automated logistics centers, the combination of compact design, collaborative robotics, and simple safety integration offers clear advantages to ensure competitiveness and scalability in the long term.
"Cell convinced us."
Christoph Heid
Head of Technology, Systems and Maintenance, Logistics Center
System Configuration and Specifications
Cell
MalocherBot Palletizer S
Robot
Doosan P3020 Cobot
Gripper
Custom-developed gripper
Software
LUNA Automation Operating System
Products
KLT containers (small load carriers)
Maximum payload
15 kg
Business Results
With automated palletizing, DEUTZ was able to completely automate another central process step and consistently further develop its logistics processes. Manual activities were reduced, throughput times stabilized, and integration into existing automation concepts – including AMR systems – successfully implemented.
The solution supports DEUTZ in continuously expanding its high degree of automation and creates the foundation for further efficiency gains in a competitive environment.
Cartons, plastic containers, bags and more. The PIAB vacuum system and LUNA pattern tools support a wide variety of packaging. We validate edge formats during project planning.
Operators can add/change carton types and pallet patterns directly in LUNA. No external programming required. This reduces changeover times and keeps throughput stable during SKU changes.
We use your labor rate, cases/minute, pallets/hour, shifts and downtime to estimate savings and payback times in months. Give us your numbers to get a customized model.
Dual-pick increases cartons/minute without expanding footprint. We map your target cycle time to pallets/hour in the ROI estimate.
Yes. We integrate safety and compliance according to EU standards (CE) with proven components (Doosan P3020, custom gripper). Details on hygiene and safety guards are determined during layout review.
