Spotlight on Stack & Wrap

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KPal Stack & Wrap: Palletizing with Integrated Load Containment

What Is Stack & Wrap Palletizing?

Our KPal Stack & Wrap (KPal SW)systems combine:

  • Robotic palletizing for precise case placement and configurable stacking patterns
  • Continuous palletizing for increased throughput—while a load finishes the wrapping process, the robot has already begun the next load
  • Integrated stretch wrapping for immediate load containment and stability
  • Coordinated controls that synchronize stacking and wrapping for maximum efficiency

Rather than conveying completed pallets to a standalone wrapper downstream, a stack & wrap system integrates both functions into a single engineered cell. This reduces material handling, eliminates transfer delays, and improves overall line flow.

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When to Consider Stack & Wrap Automation

Stack & wrap systems are particularly valuable when:

1. Floor Space Is Limited: Integrating palletizing and wrapping into one cohesive cell reduces equipment sprawl and minimizes conveyor runs.

2. Throughput Demands Are Increasing: High-volume lines benefit from synchronized stacking and wrapping to avoid bottlenecks between palletizing and load containment.

3. Load Stability Is Critical: Industries shipping mixed-SKU pallets, lightweight corrugate, shrink-wrapped trays, or unstable product configurations require consistent containment immediately after stacking.

4. Labor Is Limited or Inconsistent: Automating both palletizing and wrapping reduces manual intervention, minimizes ergonomic risk, and stabilizes staffing requirements.

5. You Need Scalable Growth: Stack & wrap systems are ideal for manufacturers planning phased automation—starting with palletizing and integrating additional end-of-line functions within the same engineered platform.

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The KPal Stack & Wrap Palletizing System builds the next load during wrap cycles, so the palletizing process is continuous.

Delivering Superior Value

Fully Integrated Engineering

Kaufman’s approach is not simply bolting two machines together. Each KPal Stack & Wrap system is engineered as a cohesive solution. Robotics, end-of-arm tooling, pallet handling, stretch wrapping, safety systems, and controls are designed to operate as a synchronized unit.

Optimized Line Efficiency - Improves uptime and maximizes units per hour. By eliminating intermediate pallet transfers, the system reduces:

  • Conveyor length
  • Accumulation zones
  • Transfer points
  • Downtime between operations
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KPal SWV - Stack & Wrap Palletizing system with vacuum end-of-arm tooling (EOAT).

Enhanced Load Quality - Especially valuable for distribution environments where loads travel long distances or through complex logistics networks. Wrapping in conjunction with stacking minimizes:

  • Load shifting
  • Product damage
  • Film waste
  • Inconsistent containment

Configurable for Your Application - The flexibility of our stack and wrap group, along with the rest of the KPal series of palletizers, allows for fast changeovers and adaptation to new SKUs without major mechanical modifications. For example, our Kpal Stack & Wrap systems can accommodate:

  • Single or multiple infeed/outfeed configurations
  • Pallet dispensers
  • Robotic pick-and-place of pallet to start each load
  • Standard or custom pallet patterns
  • Slip sheet and/or tier sheet placement
  • Multiple pallet sizes
  • Integrated labeling and/or load verification

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Start Your Automation Upgrade

Kaufman Engineered Systems brings decades of experience designing and integrating end-of-line and packaging automation across a wide range of industries. What sets us apart when it comes to configurable, future-ready systems:

  • Consultative approach – We invest time up front to understand your products, processes, people, and long-term goals, not just your spec sheet.
  • Deep mechanical and controls expertise – Our mechanical and electrical/controls engineers work side-by-side to design systems that are both physically modular and controls-flexible.
  • Simulation and proof-of-concept – We use system modeling and simulation to validate cycle times, product flows, and expansion scenarios before equipment is built.
  • Lifecycle partnership – From initial design to commissioning, training, and future expansions, we stay engaged as your needs evolve.

When you partner with KES, you’re not just buying a machine — you’re investing in a configurable automation platform engineered to grow with your business.

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