Packaging robots for efficient automation of the entire packaging chain

KUKA packaging robots enable flexible, safe and sustainable packaging processes – even in complex environments with changing products. Combined with mobile robotics and intelligent software, they deliver efficient, high-quality operations that improve consistency and ensure more reliable planning.

How is efficient automation of the entire packaging chain possible?

Automated packaging increases speed, stability and quality throughout the entire process, from infeed to pick-&-place applications to end-of-line automation in various industries. Packaging robots keep cycle times constant, provide clean and reproducible results and can be quickly adapted to new packaging types. Hygienic versions are optionally available. The interaction of software, mobile robots, vision systems and AI creates an integrated, modern packaging process that offers planning security and provides tangible support for companies. Collaborative robots (cobots) complement the process flexibly – even outside conventional systems – and support employees safely and efficiently.

Successful customer applications in use

KUKA packaging robots have been developed to facilitate manual work and increase sustainability within your production process. They offer individual solutions, can be seamlessly integrated with suitable tools and cover applications such as pick-&-place, box folding and palletizing. Numerous customers share their experiences – a glimpse into the future of robotic packaging:

Active8 demonstrates how the KR AGILUS HM can quickly and hygienically package up to 60 sandwiches per minute.

MODU System shows the use of the KR?DELTA, which takes over the dispensing spoon exactly and incorporates it into the existing packaging system.

The KR SCARA takes over the fast pick-&-place of individual confectionery products and places them in the separate chambers of the packages.

At Pakfish, the KR QUANTEC PA automatically stacks heavy boxes of fish and reliably integrates them into the palletizing system.

TRICOR uses powerful jointed-arm robots to automatically fold heavy-duty corrugated cardboard packaging and process it reliably further in the system.

Vepo Cheese packages cheese sticks fully automatically and hygienically using the KR AGILUS Hygienic Machine.

Expert advice for real packaging challenges

From the first idea to feasibility testing, simulation and implementation to service, we accompany you along the entire packaging chain, developing a solution that is practical and future-proof.

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Packaging robotics for every task along the packaging chain

Whether fast pick-&-place steps, hygienic applications or heavy packaging units, KUKA offers machines and packaging technology for every process in your company. Flexible, precise in the process and tailored to your individual requirements. This applies to both light and heavy boxes as well as to a variety of different products that are processed or packaged.

Fast and compact packaging machines

KR?DELTA

High-speed pick-and-place robots for primary and secondary packaging with high cycle requirements for compact packaging cells.

Payload: 6 - 15 kg
Maximum reach: 250 - 455 mm

KR SCARA

Jointed-arm robots with short cycle times for sorting, loading and packaging tasks with high repeatability.

Payload: 6 - 60 kg
Maximum reach: 500 - 1200 mm

KR AGILUS ultra

Compact small robots for tight packaging areas with dynamic motions, high precision and flexible integration.

Payload: 10 - 16 kg
Maximum reach: 901 - 1103 mm

Robots for hygienic packaging (food & pharmaceutical)

KR DELTA Hygienic Design

Stainless steel delta robots for hygienically sensitive packaging applications in the food, pharmaceutical and electronics industries.

Payload: 6 kg
Maximum reach: 250 mm

KR AGILUS Hygienic Machine

Small robots for compact packaging tasks with high hygiene requirements and precise handling in sterile environments.

Payload: 10 kg
Maximum reach: 901 - 1101 mm

Hygienic oil robot variants

Industrial robots with food-compatible lubrication for packaging and palletizing tasks in sensitive areas.

Payload: 6 - 180 kg
Maximum reach: 700 - 3195 mm

Flexible all-round packaging robots for medium & heavy packaging

KR IONTEC ultra

Robust packaging robot for medium loads with high stability for handling boxes, containers and other packages.

Payload: 90 - 120 kg
Maximum reach: 2305 - 2702 mm

KR QUANTEC PA

End-of-line palletizer for exact stacking of boxes and mixed containers for structured packaging processes.

Payload: 120 - 240 kg
Maximum reach: 3195 mm

KR FORTEC ultra PA

Heavy-duty palletizing robots for packaging output with high precision and process reliability for large units.

Payload: 550 - 800 kg
Maximum reach: 3200 mm

Cobots and AMR for collaborative and seamless packaging processes

Cobots

Collaborative robots perform flexible packaging tasks directly on the line – safe, precise and easy to integrate. (Cobot payload: 3 -?15?kg)

Mobile cobots

Mobile cobots combine gripping and transport and support various activities between packaging stations. (Cobot payload: 11 - 15 kg, platform payload: 100 -?200?kg)

mobile-manipulator-and-mobile-cobot-KMR-iisy

AMR

Mobile autonomous transport robots move packaging materials, products and pallets autonomously between all stations. (AMR payload: 100 -?25,000?kg)

Packaging robots in the online shop

View used packaging robots

What are the advantages of automated packaging with KUKA?

High throughput thanks to high-speed robotics & software
- Optimum multi-robot tuning for high cycle performance
- Fast pick-&-place applications for dynamic packaging processes
- Continuous synchronization of conveyors and product flow
Hygienic solutions for sensitive areas
- Food-compatible materials and lubricants for product-related applications
- Broad robot portfolio for areas with strict hygiene requirements
- Compatible with Vision systems for clean and controlled processes
Flexibility for changing packaging requirements
- Solutions from small parts packaging to heavy transport packaging
- Mobile and stationary robots for flexible process chains
- Fast, software-supported adaptation to new package formats or product variants
Quality assurance & digitalization at every step
- Camera systems and digital monitoring for position detection and quality control
- Simulation tools for planning, optimization and training without system downtime
- Intuitive user interfaces for quick setup and adaptations

Digital solutions for packaging technology

iiQKA.OS2 - An operating system for simple, scalable packaging automation

The operating system provides the basis for all modern KUKA packaging applications. It ensures?uniform, intuitive operation, speeds up start-up and enables fast format changes?as well as stable processes in your company – from high-speed pick-&-place to end-of-line automation.

Ideal for: Packaging systems with frequent adaptations, new or expanded cells, intuitive operator control concepts.

More about our operating system iiQKA.OS2

An operating system for versatile robotics requirements

Simulation tool iiQWorks.Sim (digital twin)

iiQWorks.Sim allows packaging cells to be planned, tested and optimized completely virtually. Layout, cycle times, material flow or robot paths can be analyzed in digital twin – without interfering with the real environment. Companies therefore shorten start-up, reduce standstill and make informed decisions.

Ideal for: Planning of new packaging cells, optimization of existing lines, training.

More about the simulation software iiQWorks.Sim

Virtual planning of packaging cells: Simulation and digital twin with iiQWorks.Sim for quick start-up

iiQWorks.Copilot – AI-supported assistance for simulations

The assistant?simplifies complex packaging tasks with AI-supported assistance functions. It supports the simulation of motion sequences, the adaptation of parameters or error management – ideal for teams wishing to program and operate packaging robotics more efficiently.

Ideal for: Engineering teams, integrators, operators, quick adaptations.

More about the AI copilot for robot simulation

iiQKA.mxAutomation – Seamless robot controller from the PLC for palletizing & packaging

The certified PLC interface can be used to control robots directly from the PLC – ideal for packaging systems in which the control logic is already integrated in the machine or line PLC. Motions can be defined without more in-depth knowledge of robotics, which makes the integration of palletizing, feeding and handling particularly easy.

Ideal for: Machine builders / integrators, line controllers, end-of-line automation.

KUKA.PickControl for coordinated high-speed pick-&-place applications

The robot software?controls several robots simultaneously and ensures optimum cycle performance in packaging lines. The software solution dynamically distributes orders, synchronizes machines and conveyors and enables pick-&-place processes in which every gram and every millimeter counts – ideal for high speeds and repeatability.

Ideal for: Multi-robot scenarios, fast product placement, sorting, grouping.

More about our KUKA.PickControl software

Increased packaging productivity with KUKA.PickControl – the simple solution for coordinating multiple robots

KUKA.FlexPal – Intuitive software for flexible palletizing layouts

The palletizing software is a user-friendly solution for palletizing tasks in the packaging. New stacking patterns are quickly created or adapted in the editor – without programming. Complex mixed-case applications are also supported so that packaging units are stacked in a stable, efficient and space-optimized manner.

Ideal for: End-of-line palletizing, product changes, small batch sizes, variable packaging.

More about our palletizing software

Simulate packaging processes in minutes

In the demo simulation, select suitable packaging robots and grippers for future systems.

FAQ on packaging robots for the entire packaging chain

What packaging stages can be automated?

Primary, secondary and tertiary packaging including palletizing, depalletizing and material flow.

What packaging tasks can a packaging robot typically perform?

KUKA robots cover a wide range of typical packaging tasks, including:

Pick-&-place of products of all kinds
Cartoning and box folding
Packaging & repackaging
Sorting, order picking and feeding
Palletizing & depalletizing
End-of-line automations such as sealing or labeling

For which industries are packaging robots useful?

Wherever products are packaged, repackaged or palletized – regardless of product type or industry – whether in food, pharmaceutical, consumer goods or other industries.

How flexible are KUKA packaging solutions?

Modular, scalable and adaptable to new products, formats and quantities.

What role does software play in packaging automation?

Software ensures planning, cycle time, process stability and fast conversion.

Can I automate step by step?

Yes. KUKA solutions are modular and grow with your needs.

Automated packaging as an interface

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