The year of the pallet: from uniform loads to mixed-SKU, real-time builds  

Palletizing was hard to miss at Modex 2026 in Atlanta. Across the show floor, robots were stacking, unstacking, and rebuilding loads, with demos running in nearly every booth.

That visibility points to the growing importance of end-of-line automation and transporting products from the packaging line to the warehouse. At the same time, the focus is shifting to the pallet itself – how it’s built, what goes on it, and how products move through increasingly varied environments.

One of the clearest examples is the rise of the “rainbow pallet,” where multiple SKUs are combined on a single load, often mixing product types and packaging formats as demand continues to expand.

Across the event, companies including Lucas Systems, Fanuc America, Piab Group, and Angelini Technologies highlighted how palletizing is evolving. That change is being driven by real-time decision making, greater variability, and artificial intelligence (AI) to improve efficiency in complex operations. 

“This is the year of the pallet,” said Joshua Franker, head of marketing at Lucas Systems, during an interview with Packaging OEM. “If there’s damage to the pallet, damage to the goods, it comes back and costs the warehouse. That’s a very visible, tangible thing that we’re able to address.”

With that in mind, Modex highlighted how software and robotics are working in tandem to make that possible, while also capturing the knowledge traditionally held by experienced workers.

Building pallets during picking

Lucas Systems is pushing that change into the picking process itself with its Dynamic Pallet Builder software, which uses AI to construct pallets based on order information, product attributes, and warehouse layout.

“We’re building the pallets while picking, so it’s not requiring you to pick the items and then build the pallets elsewhere,” said Franker. “It allows us to offer the ability to build pallets exactly how you want to.”

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Alongside that, the company’s Best Pallet Matching technology determines which loads should be built together, reducing repeat trips and extra steps across the warehouse floor.

“This is all happening in real time,” said Franker. “When a worker goes to get their next assignment, in that exact moment, we can put the best two or three pallets together to minimize travel and really boost efficiency.”

This moves operations from a fixed plan at the start of the shift to a system that continuously adjusts based on orders, priorities, and current conditions on the floor.

Franker added that these efforts also remove one of the biggest dependencies in palletizing: experience. “We make sure the pallet is built the same way every single time, and get rid of the tribal knowledge that exists,” he said. “The experienced worker knows how to build it, but the new worker can also build it just as well.”

By optimizing how pallets are built and routed in the moment, companies are seeing measurable benefits.

“We have customers who use this and are seeing close to a million dollars a month in savings,” said Franker.

Robotics takes on mixed SKU palletizing

Robotic systems are being pushed to handle the product mix in everyday operations. That was on display at Fanuc America’s booth, where an industrial robot used AI to stack mixed products, including macaroni and cheese, Kleenex, and Ziploc bags, onto a single pallet.

The system was equipped with a 3DV/1600 3D vision sensor and an IPC-enabled locator to identify pick locations for difficult products.

“Those are two separate cases that we’re picking from, and it’s very difficult in traditional vision systems to detect that. We’re able to utilize our AI and vision-enabled software to detect that difficult part of the layer,” said Geoff Dawson, director of sales – executive sales team at Fanuc America.

He added that Fanuc is seeing a lot of end-of-line applications for mixed loads, especially in e-commerce. 

“So, when they get to a store, they don’t have to break down the whole pallet. They’re breaking down a pallet of the stuff they need,” said Dawson. 

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It reflects how goods move through e-commerce environments, where shipments are smaller, more varied, and more frequent.

“The industry is definitely leaning towards the mix and variability,” said Jessica Juhasz, engineering manager at Fanuc America. “Being able to adapt to that change is what we’re moving towards.”

Gripping tools adapt to mixed packaging types

To support the growing mix of packaging materials, Piab Group previewed its BLFF suction cup, which is set to be available this fall. It’s designed to handle a range of packaging types, from flexible bags to rigid cans, without needing multiple tools.

David Garcia, area sales manager for Piab Group’s vacuum automation and robotic gripping division, demonstrated the tool moving large bags of pet food and cases of bottled water.

“It solves a lot of the problems for my customers and makes it really simple for them to have a reliable solution that’s going to let them save money, be more efficient, and actually increase their production,” he said.

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As mixed-SKU operations rise, flexibility is becoming more important.

“A lot of people are handling a lot of mixed materials when you’re doing pick and place,” said Garcia. “There’s a lot of automation happening in warehouses.”

Software adapts as loads change

Handling that complexity means systems need to adapt as conditions change. Luigi De Vito, CEO of Angelini Technologies, said that’s where orchestration comes in, with software that’s constantly re-evaluating what’s happening during the build process and adjusting as needed.

The company introduced two automation systems aimed at improving how parcels are processed in logistics environments. DEPAX uses robotics and computer vision to handle parcels of varying sizes, while PAX Stability evaluates whether an item is stable before it enters the main line. Unstable items are automatically removed before they can disrupt downstream operations.  

“It’s an orchestrator that’s recognizing what’s on the pallet, then it’s understanding which is the best sequence to take, and then it’s executing,” he said.

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This creates a continuous loop where the system sees what’s happening, adjusts, and responds. This is especially important in highly variable rainbow pallet conditions where mixed case sizes and formats are randomly distributed.

“It’s about productivity and repetitive efficiency,” said De Vito.

He added that this approach reflects a broader shift in how software is being used in warehouses, adding that it remains a critical layer in modern operations.

“The big value of software is that we’re able to understand where it is and what it needs to do based on what it finds,” said De Vito. “We are going from deterministic processes to completely unpredictable processes.”

Angelini Technologies is also expanding its North American footprint through its minority stake in Lab0, a robotics company focused on container and truck unloading.

Stacking changes in end-of-line operations  

The innovations on the Modex show floor don’t simply reflect how pallets are stacked and assembled. They point to a shift in how decisions are made.  

Software determines how loads should be built as conditions change. Robotic systems execute those decisions, and orchestration layers adjust as operations unfold.

At the same time, the knowledge on how to build a stable pallet is being engineered into the system, rather than relying on experienced workers to guide it.

As the workforce changes, the shift matters. It’s why 2026 is shaping up to be the year of the pallet – and it’s being rebuilt in real time.