Custom Palletizer Machines

Aagard palletizers automatically build consistent, stable pallets, reducing manual stacking and keeping end-of-line flow moving. Each system is engineered to your product, speed, and footprint, and can include features like dual-cell palletizing, slip and tier sheet handling, and integrated stretch wrapping.

Built for consumer-packaged goods manufacturers in food and beverage, personal care, and household products, Aagard palletizers are purpose-built systems, not catalog machines. If your line has specific throughput requirements, a constrained footprint, or changeover complexity that off-the-shelf equipment can't handle reliably, that's exactly where Aagard's application-first engineering approach is designed to help.

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Aagard Palletizer & Stretch Wrap System
Palletizer solutions
Case packer and palletizer system
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Where Aagard Palletizers Are Used

Built for the Production Challenges Off-the-Shelf Systems Can't Handle

Most manufacturers don't come to Aagard because they need a palletizer. They come because they have a specific problem at the end of the line that a catalog machine couldn't solve.

The scenarios below represent the most common situations. If your line matches one of them, an Aagard system is likely worth a closer look.

Production Scenario Configuration Match

Manufacturer needs to reduce manual stacking and stabilize staffing across multiple shifts

Semi or Full Auto Palletizer

High-throughput line can't afford stops for pallet swaps

Continuous-Flow Palletizer

Plant is integrating a new cartoner or case packer and wants unified end-of-line controls

Fully integrated palletizer with single, unified controls

Facility has a tight footprint and needs palletizing and stretch wrapping in the same envelope

Full Auto Palletizer + Stretchwrapper

Line runs many SKUs and needs repeatable changeovers without constant troubleshooting

RapidLaunch™ (Monitored or Automatic)

Customer is experiencing pallet quality issues: load shifting, damage in transit, warehouse rejections

Engineered pallet build with options like slip and tier sheet handling and integrated wrapping

When your application, footprint, integration requirements, or changeover complexity require a purpose-built system, that's where Aagard's process is built to deliver.

Not Sure If a Palletizer Is Right for Your Line?

Engineering Kickstart is a structured, application-first evaluation where you work directly with Aagard engineers to define requirements, explore concepts, and align on the right configuration before committing to a full build. It reduces risk up front.
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About Our Process

Configure Your Palletizer Around Your Line

Every Aagard palletizer starts with your application: your product, your line rate, your footprint, and your operational goals. From that baseline, you select from a documented set of options organized around the outcomes that matter most to your team.

The options below represent our most commonly configured selections, not the full scope of what's possible. Our team is happy to discuss anything not listed here.

Pallet Handling & Automation Level

The foundation of your system. These options define how much automation you need at the end of the line and whether your configuration requires continuous operation.

Option What It Delivers

Semi/Full Auto Palletizer

Automates end-of-line pallet building to reduce manual stacking while maintaining consistent pallet quality

Full Auto Palletizer + Stretchwrapper

Delivers a finished, wrapped pallet automatically, improving throughput and load integrity in one integrated system

Dual Bay Palletizer

Enables pallet swaps without stopping production to keep high-volume lines running continuously

Pallet Magazines/Dispensers (GMA, CHEP)

Automates pallet staging so operators aren't manually placing pallets at the cell

Pallet Discharge Conveyors/Transfer

Moves completed pallets out of the cell and into your downstream flow without manual intervention

Pallet Load Integrity

For lines where load stability, shipping compliance, or warehouse requirements drive the specification.

Option What It Delivers

Slipsheet/Tier Sheet Magazine

Automatically places sheets between layers to improve load stability and meet warehouse and shipping requirements

Stretchwrapper + Turntable

Adds integrated wrapping in the same footprint so pallets ship more securely without a separate downstream wrapper

Pallet Labeler Integration

Applies labels to finished pallets to meet warehouse, retailer, or shipping requirements

Pallet Barcode Verification

Confirms label accuracy and pallet identity before the load leaves the cell

Changeover & Usability

For lines running multiple SKUs or requiring fast, repeatable restarts after recipe changes.

Option What It Delivers

RapidLaunch™ (Monitored)
Guided changeover with verification helps teams restart faster and reduces errors after recipe changes

RapidLaunch™ (Automatic)

The fastest changeover option; automates adjustments where practical to minimize downtime and reduce operator burden

Additional HMI

Adds an extra operator station for better line access, especially on larger systems or multi-sided workflows

FactoryTalk Optix HMI

Provides an enhanced operator experience with richer diagnostics, embedded training, and documentation on the HMI

Training Videos

Embeds step-by-step guidance directly in the HMI so operators have reference material at the machine

Compliance & Food Safety

For facilities with specific regulatory, plant, or retailer compliance requirements.

Options What It Delivers

Metal Detectable Wire Ties

Reduces contamination risk in food-grade environments

Food Grade Lubricant

Meets food-safe lubrication requirements for applicable contact points

UL Electrical Panels

Provides UL-labeled control panels to support compliance and plant standards in the U.S. and Canada

Circuit Breaker Upgrade

Available when application or plant electrical standards require it

Controls, Integration, & Remote Support

For engineering teams evaluating how the palletizer connects to the rest of the line and to Aagard's service team.

Option What It Delivers

LED Diagnostic Lighting

Improves visibility at key access points and helps teams troubleshoot faster when a fault occurs

Forensics Camera System

Captures video of events around stops to speed root-cause analysis and reduce repeat downtime

Remote Support (TeamViewer)

Enables Aagard service to connect remotely for faster troubleshooting and reduced time to recovery

Ethernet IP Module

Connects the palletizer to your plant network for data exchange and line visibility

Network Architecture
Defines how the system integrates with your plant's OEE, data, or control infrastructure

Plant Network/OEE Integration
Supports broader production visibility and reporting requirements
case packer and palletizer system

What Every Aagard Palletizer Includes as Standard

Engineering & Safety Standards Built into Every Machine

Before you select a single option, every Aagard palletizer ships with a documented baseline of engineering, safety, and controls standards. The foundation is consistent and proven. The configuration builds on top of it.

Every Aagard palletizer ships fully tested before leaving the facility. Controls, safety circuits, and key machine functions are verified prior to shipment. When materials are available and the project scope includes it, a full run-off with customer product and materials is completed.
Standard What It Means for Your Line

Category 3/Performance Level d Safety Design

Safety architecture meets Category 3/PLd requirements, documented and consistent across all Aagard machine categories

Pilz Guard Switch

Mechanical locking and release - High safety / clear lock state

NEMA 12 Rated Electrical Panels

Control panels rated for industrial environments; UL-labeled panels available as an upgrade

UL-Certified Electrical Components

Electrical components are UL-certified as standard

Rockwell Automation Controls Platform

Controls architecture built on a documented, serviceable platform with broad parts availability

Single Unified Controls Architecture

Upstream and downstream equipment can be integrated under one control system, reducing handshakes and simplifying troubleshooting

HMI-Embedded Documentation

Maintenance guides, changeover instructions, and reference materials accessible at the machine

Documented Machine Standards

Every build references Aagard's documented standards so your engineering team knows what they're getting before the project starts

How a Custom Palletizer Project Works at Aagard

One of the most common hesitations on a custom machine project isn't the machine itself. It's not knowing what happens after you fill out a form. Here's the full path from first conversation to a commissioned system running on your floor.

  1. Application Discussion

    Every project starts with a conversation about your application: what you're running, your line rate, your footprint, and your goals. This is an engineering intake, not a sales call.

  2. Engineering Kickstart

    Engineering Kickstart is the standard entry point for all Aagard projects. It's a structured, application-first evaluation where you work directly with Aagard engineers to define requirements, explore concepts, and align on the right configuration before committing to a full build, in order to reduce risk up front.

  3. System Design & Build

    Once requirements are defined and scope is locked, Aagard engineers design and build your system. This phase includes controls architecture, mechanical design, integration planning, and documentation. Your engineering team has visibility into the process and clear handoff points.

  4. Factory Acceptance Test (FAT)

    Every system goes through standard pre-shipment testing before it leaves Alexandria, MN. For projects where scope and preference support it, an expanded FAT demonstration package is available so your team can witness performance firsthand before the machine ships.

  5. Installation & Commissioning

    Aagard technicians handle installation and commissioning at your facility. Installation and commissioning estimates, along with shipping estimates, are provided with your quote. Timelines depend on system complexity and site readiness.

  6. On-Site Training

    Operator and maintenance training is included as part of the commissioning package. Additional training is available as your team grows or shifts change.

  7. Ongoing Support via Aagard Assurance™

    After go-live, your line is supported through Aagard Assurance™: a dedicated account contact, a spare parts list for your specific configuration, and 24/7 remote service availability via TeamViewer. 

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Why Teams Choose Aagard

Purpose-built for your line, not pulled from a catalog. Here's what that means in practice:

Reduced manual stacking labor and improved ergonomics across all shifts
Consistent pallet builds that reduce load damage and warehouse rejections
Continuous-flow operation on high-volume lines through dual-cell palletizing
Faster changeovers with fewer errors using RapidLaunch™ guided or automatic changeover
Smaller footprint with higher capability, including integrated stretch wrapping in the same envelope
Unified controls for the palletizer and integrated upstream/downstream equipment
Category 3/Performance Level D safety design with magnetic locking guard doors and documented safety circuits
Maintenance access and HMI-embedded documentation designed in from the start
Documented machine standards delivered with every system

Designed to your layout and material flow, not forced into a catalog footprint

Aagard Assurance after go-live: dedicated contact, spare parts list, and 24/7 remote service availability

Palletizer FAQs

Does Aagard make fully custom palletizers, or are they based on standard configurations?

Aagard palletizers are custom-engineered to each customer's application, but built from a documented set of standards and options. That means your system is tailored to your line, layout, and product without the risk and timeline of a fully custom build.

How do I evaluate a palletizer without published specifications?

Start with your application: what you're palletizing, your line speed, your facility layout, and your labor goals. Aagard's engineering team uses that information to scope the right system. Our Engineering Kickstart is designed specifically for this early evaluation phase.

Can the palletizer keep running while we swap pallets?

Yes. The Dual Bay Palletizer option allows continuous operation by enabling pallet swaps without stopping the line. It's the right configuration for high-volume lines where any pause in end-of-line flow creates upstream backup.

Can Aagard integrate stretch wrapping into the same system?

Yes. Aagard offers integrated stretch wrapping as part of the palletizer system, including a Stretchwrapper + Turntable and a Full Auto Palletizer + Stretchwrapper option. Both keep the pallet wrapping step within the same footprint rather than requiring a separate downstream station.

What safety standards does an Aagard palletizer meet?

Every Aagard machine is built to Category 3 safety standards with magnetic locking guard doors and controlled stop sequences. Electrical panels are NEMA 12 rated with UL-certified components available as an option. Safety architecture is documented and consistent across all machine categories.

How long does installation and commissioning take?

Installation and commissioning timelines depend on system complexity and site readiness. Aagard provides installation and commissioning estimates as part of the quoting process, and both services are performed by trained Aagard technicians. On-site operator and maintenance training is included as part of the commissioning package.

What support is available after the machine is commissioned?

Aagard offers remote diagnostics via TeamViewer, HMI-embedded documentation and maintenance guides, changeover training videos, and on-site training at commissioning. Ongoing support is available through Aagard's service team, keeping your line running after go-live.

What information do you need to size or quote a palletizer?

We start with the basics: case size and weight, line rate, pallet patterns and pallet type, and your available footprint. From there, we confirm any requirements like slip and tier sheets, integrated stretch wrapping, or labeling. If you're still early, Engineering Kickstart helps define the right scope before moving to a full build.

What pallet types can you handle, and do you support pallet dispensing and magazines?

We build around your pallet requirements—commonly GMA and CHEP, and custom pallets when needed. For higher automation, we can include pallet dispensing and magazines so operators aren't manually staging pallets at the cell.

Do you support tier sheets, slip sheets, and pallet labeling and barcode verification?

Yes. These are common options. We can integrate slip and tier sheet handling and pallet labeling, including verification, to match your warehouse and shipping requirements.

How many SKUs and pallet patterns can a system run, and how are recipes managed?

Recipes are managed through the HMI so operators can select the right SKU and pattern quickly and repeatably. The number of SKUs and patterns depends on your application. For faster, more consistent changeovers, RapidLaunch™ (Monitored or Automatic) helps guide and verify setup.

What does Aagard Assurance include after commissioning?

Aagard Assurance is our long-term support model: a dedicated point of contact, proactive follow-up, and access to expert service when you need it. Many systems also include remote support via TeamViewer and built-in HMI documentation to speed troubleshooting.

What throughput and rate range can you support, and what factors determine it?

We size each palletizer to your required cases per minute and pallet patterns. Rate depends on factors like case size and weight, pattern complexity, and whether you need continuous operation (for example, dual-cell palletizing to avoid stops during pallet swaps). We confirm the right configuration during scoping—often through Engineering Kickstart.

What's the typical lead time for a custom palletizer?

Lead time depends on scope, complexity, and production schedule. The biggest drivers are locking requirements early, long-lead components, and having representative materials available for FAT. Once scope is defined, we provide a clear project schedule with your quote.

How much floor space is required, and can you design around a constrained footprint?

Footprint depends on automation level and options like dual-cell operation, pallet dispensing, and integrated wrapping. If you're space-constrained, that's exactly where Aagard's custom engineering approach helps: we design to your layout instead of forcing a catalog footprint.

What utilities are required, and do you provide utility consumption estimates?

Answer goes here.

Can the system handle mixed-case pallets, rainbow pallets, or multiple pallet patterns on the same line?

Answer goes here.

How do changeovers work and what's a typical changeover time for multi-SKU lines?

Answer goes here.

Can you integrate with our existing conveyors, case packer, labelers, or stretch wrapper—or replace only part of the end-of-line?

Yes. We can deliver a full end-of-line solution or integrate into your existing conveyors and equipment. We define clear integration boundaries early and build the controls handshakes and HMI visibility needed to keep the line running smoothly.

What information and materials are needed for FAT and run-off?

For the best FAT, we use materials that match your production line: cases, pallets, and any slip/tier sheets or wrap film included in the scope. We'll align on pallet patterns and acceptance criteria up front and document what's needed for a meaningful run-off.

What spare parts do you recommend at start-up, and do you provide a spare parts list?

Yes. We provide parts documentation and can recommend a start-up spares package based on your configuration and uptime goals—typically focused on wear items and critical components to reduce downtime risk.

Do you offer service agreements, preventive maintenance support, or training refreshers after go-live?

Yes. Support continues after go-live through Aagard Assurance and our service team, including remote troubleshooting and follow-up support. We can also provide additional training as your team grows or shifts change.

Tell Us About Your Line

We'll Tell You How We'd Build for It

Do you have a specific situation at the end of your line that off-the-shelf equipment hasn't handled well?

Tell us about it. Aagard will follow up to schedule a short application discussion to understand your product, speed, layout, and goals. From there, we'll recommend the best-fit configuration and next steps.

Custom scope. Documented standards. Proven implementation. Built in Alexandria, MN.