38 n ROBOTICS AND AUTOMATED MANUFACTURING July/August 2025 www.drivesncontrols.com How AI is transforming end-of-line packing and palletising Businesses have always tried to operate faster and more effectively, and automation has helped them achieve this. Now, though, change is a daily occurrence, fuelled by advances in artificial intelligence (AI). For more than 40 years, I have helped British factories and packhouses to automate their end-of-line packing and palletising systems. In the past decade, we’ve seen the presence of cobots (collaborative robots) increase, along with the use of AMRs (autonomous mobile robots). These intelligent robots can move around and make decisions independently in dynamic environments. They are already being used in logistics, automotive and consumer goods businesses, and we will see them become more prevalent in the food industry over the next few years. Another significant and rapid change I've seen in the past 18 months is the increasing use of artificial intelligence (AI). At its heart, AI is about developing machines that can make decisions based on real-time information that they receive and analyse. In the context of end-of-line automation, this goes far beyond simply repeating programmed steps. Today's systems can analyse data from sensors and cameras, adapt to shifting production needs, and even learn from experience to improve over time. For instance, AI-driven vision systems can now identify different products on a conveyor, regardless of minor variations in size or shape. This makes it possible to sort, orient, and pack items with an accuracy and speed that manual labour cannot match. In palletising applications, AI algorithms can determine the most efficient stacking patterns on-the-fly, optimising space and stability for every load. At Pace Mechanical Handling, we’ve worked with a variety of businesses, including fresh produce packers, protein processors, aggregate suppliers, and more. Each faces unique challenges, but the benefits of AI-powered automation are remarkably consistent: n Reduced downtime By monitoring equipment health in real-time, AI can alert people to potential component failures before they occur. This allows for planned maintenance and fewer unexpected stoppages. n Greater flexibility Automated systems can switch quickly between product types or packaging formats, which is invaluable for businesses dealing with seasonal changes or diverse product lines. n Enhanced quality control AI can spot inconsistencies or defects that might escape the human eye, ensuring that only products that meet required standards reach the customer. One of our recent projects involved a salad packhouse that was struggling with unpredictable demand and a shortage of skilled labour. By integrating AI-enabled robotic palletising, they were able to automate changeovers between different pack sizes and formats, keeping the line moving efficiently, no matter what the day brought. Self-optimising systems Looking ahead, we’re seeing a move from automated processes towards truly autonomous systems. These next-generation systems don’t just follow pre-programmed instructions – they monitor their performance, make adjustments on-the-fly, and even schedule maintenance when needed. This level of autonomy is still emerging, but early adopters are already reporting improvements in throughput and reliability. We’re exploring ways to incorporate this intelligence into our machines so they adapt to real-world conditions and keep production running smoothly with minimal human intervention. A major advantage of AI in the factory is its ability to make decisions based on real-time information and data. Modern packing and palletising lines generate a wealth of information – cycle speeds, energy consumption, error rates, and much more. AI can sift through this data, uncovering patterns and highlighting opportunities for improvement that might otherwise go unnoticed. In manufacturing, change is a constant. Today, it's happening faster than ever, argues Nick Cesare, owner of Pace Mechanical Handling, which specialises in automated and robotic end-of-line packing and palletising systems. Collaborative robots can operate safely alongside human workers
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