How Smart Automation is Solving Labor Shortages and Boosting Productivity in Warehouses

As labor shortages continue to challenge logistics, manufacturing, and distribution industries, managers are turning to automation to maintain productivity. One of the most efficient solutions on the market today is the Universal Robots UR20 collaborative robot (cobot) with the SMC ZGS Foam Vacuum Gripper, Robotiq PE20 Palletizer, and Regal Rexnord ModSort. This combination is proving to be a game-changer for businesses struggling with high turnover rates and increasing operational costs.

From e-commerce fulfillment centers to food and beverage warehouses and automotive manufacturing, companies are deploying this compact, high-performance palletizing system to increase efficiency, reduce labor costs, and future-proof their operations.

1. E-Commerce Fulfillment: Meeting Surging Demand Without Extra Labor

Industry Challenge: With the rise of online shopping, fulfillment centers must process and ship thousands of orders daily. Manual palletizing is slow, labor-intensive, and contributes to high employee turnover.

How the UR20 Cobot Helps:

• Handles up to 40 lbs per box and stacks up to 7 feet high—eliminating strain on human workers.
• Requires minimal floor space—perfect for high-density warehouse operations.
• No expensive wiring or complex installation—runs on a standard single-phase outlet.

Real-World Example: Companies like Amazon and Walmart have automated large portions of their fulfillment operations using robotic palletizers to speed up logistics. Similar technology is now accessible to small and mid-sized businesses looking to gain a competitive edge.

Productivity Boost: Fulfillment centers deploying collaborative palletizing robots have reported a 30-50% increase in efficiency, with fewer errors and lower injury rates.

2. Food & Beverage Warehouses: Keeping Up with Demand While Reducing Injury Risks

Industry Challenge: The food and beverage sector relies on consistent, high-speed palletizing for packaged goods, but high turnover and strict safety regulations make manual labor an ongoing challenge.

How the UR20 Cobot Helps:

• Gentle vacuum gripping ensures secure handling of packaged beverages, dairy products, and snacks.
• Reduces worker strain—automating repetitive lifting prevents common injuries.
• Easily integrates with existing conveyor systems, thanks to ModSort technology.

Real-World Example: Bob’s Red Mill, a natural foods manufacturer, recently deployed a UR20 cobot-powered miniPAL+ palletizer. By automating its palletizing tasks, the company was able to free up four workers per day, improve order accuracy, and eliminate bottlenecks.

Productivity Boost: Automated palletizing has cut down product damage by 40% while increasing throughput, ensuring that businesses meet growing customer demand efficiently.

3. Automotive & Electronics Manufacturing: Protecting High-Value Components

Industry Challenge: Precision industries require careful handling of delicate components and high-value electronics. Manual palletizing increases the risk of product damage, leading to costly defects and waste.

How the UR20 Cobot Helps:

• Consistent motion control ensures precision placement, reducing breakage.
• Flexible and scalable automation—can handle different package sizes and weights.
• Easily programmable for different tasks—ideal for short production runs or custom orders.

Real-World Example: Ornua, a major dairy cooperative, adopted a UR20-based automation solution to palletize dairy products. The system eliminated labor bottlenecks, ensured product integrity, and enabled rapid scaling during peak demand periods.

Productivity Boost: Automotive and electronics manufacturers using robotic palletizers have seen a 25% increase in output while reducing material waste by up to 35%.

Why Automation is the Key to Overcoming Labor Shortages

As workforce challenges persist, companies that fail to automate will face higher costs, production delays, and reduced competitiveness. The UR20 palletizing solution is an ideal entry point for businesses of all sizes because it offers:

✔ Fast ROI—Pays for itself in as little as 12-18 months.
✔ Minimal training required—Operators can program the system in just a few hours.
✔ Scalability—Can be easily adapted to new product lines and production changes.

Take Action: Future-Proof Your Business Today

With labor shortages and rising costs, waiting to implement automation is no longer an option—it’s a necessity. Contact Automation Distribution today at 1-888-600-3080 to discuss how this powerful collaborative palletizing solution can transform your operations.