On October 22, 2026, packaging journal reported that Werner & Mertz, the German manufacturer of cleaning, care, and washing products known for brands such as Frosch, automated the palletizing of approximately seven-kilogram cartons in an existing production line using a compact robot cell from Koch Robotersysteme (part of Koch Industrieanlagen GmbH). Previously manual stacking of these cartons onto pallets has been replaced by a standardized movable robot cell with two independent palletizing stations, adapted specifically for the site after demonstration at Fachpack in Nuremberg. The companies have collaborated on automation projects since 2004.
The cell integrates into the existing line with supplemental conveying technology and a suction gripper adapted to the carton formats, processing both new and used pallets. With a footprint of about 9.5 square meters, it suits compact areas; dual stations allow pallet changes on one while the other continues operation, and the cell can be relocated via forklift for flexibility. Security includes a protective fence, light barriers, and access logic.
Operated via touch panel, it supports additional palletizing patterns through optional software. In the Werner & Mertz application, the robot picks three cartons simultaneously, achieving up to 540 cartons or ten pallets per hour, with 18–24 cartons per layer and three layers per pallet depending on product and pattern. Beyond throughput gains and process stability, the automation provides physical relief for employees by eliminating manual lifting of heavy cartons, improves production planning, and accommodates future product variants without full line redesign.
Commissioning occurred within weeks, including gripper adaptation, fine-tuning, and training for operations and maintenance staff. This exemplifies a modular approach: adapting standardized systems to existing conveyor technology, layouts, and formats rather than complete rebuilds, relevant for packaging lines seeking to address skilled labor shortages, reduce costs, and maintain flexibility. Thomas Theis, Sales Manager at Koch, noted automation as an economically sensible lever for these challenges.
The project demonstrates how compact robotic cells deliver high cycle performance (three cartons per grip) in constrained spaces while enhancing reliability for outbound logistics.