How TIDI Merchandise elevated palletizing productiveness by 30% with automation

TIDI Products, a global manufacturer of infection prevention and patient safety products, transformed its end-of-line operations by automating with Lean Palletizing. The result: measurable gains in productivity, safer working conditions, and more efficient use of labor.

This case shows how robotic palletizing can directly improve manufacturing performance with clear, repeatable results.

Key results at a glance

30% increase in palletizing productivity (first cell)
25% additional productivity gains (subsequent cells)
2× performance improvement by combining work cells
Reduced labor from two operators to one per cell
Significant reduction in strain and injury risk

The problem: manual palletizing limited production capacity

Before automation, palletizing at TIDI Products was fully manual. Operators handled multiple tasks, including:

Building boxes
Filling and sealing them
Transporting and stacking them on pallets

This created two critical bottlenecks:

Labor inefficiency
One operator often had to manage multiple stations, reducing focus and throughput.

Production delays and lost revenue
Backlogs increased, and the company was forced to decline orders.

Not only was manual palletizing slow, it prevented the company from scaling.

The solution: Robotiq Lean Palletizing

TIDI Products deployed Robotiq palletizing solutions to automate repetitive and physically demanding tasks at the end of the line.

The system provided:

Consistent palletizing performance
Flexibility across product lines
Fast operator adoption due to ease of use

This allowed the team to quickly move from manual handling to a scalable, automated process.

Result 1: 30% productivity increase in the first deployment

The first palletizing cell delivered a 30% increase in productivity.

This immediate gain came from:

Eliminating manual handling time
Reducing operator movement between stations
Increasing overall line speed

For manufacturers evaluating ROI, this shows how a single automation project can quickly unlock capacity.

Result 2: Repeatable gains across multiple cells

After the initial success, additional palletizing cells were deployed.

Each new cell delivered:

25% productivity improvements on average

This demonstrates an important principle of automation: once a process is standardized, improvements become repeatable and scalable.

Result 3: Doubling output by redesigning the workflow

Automation enabled TIDI Products to rethink its production layout.

By combining two workstations into one:

Output per cell doubled
Operator requirements dropped from two to one
Uptime increased across operations

This is a key insight: robotic palletizing doesn’t just automate tasks; it enables process redesign for higher throughput.

Result 4: reducing labor constraints while increasing efficiency

Labor challenges were a major driver for automation.

After deployment:

One operator can now manage multiple processes
Workers focus on higher-value tasks like machine operation
Overall efficiency improves without increasing headcount

This helps manufacturers maintain output even in tight labor markets.

Result 5: improving worker safety and ergonomics

Manual palletizing required repetitive lifting of boxes weighing up to 25 lbs (11kg).

This led to:

Strains and sprains
Fatigue and lost workdays

With robotic palletizing:

Injury risks were significantly reduced or eliminated
Physical strain on workers decreased
Jobs became less physically demanding

Improving ergonomics also supports long-term workforce retention.

Result 6: consistent output and improved product quality

Manual palletizing required training and still introduced variability.

Automation delivered:

Consistent pallet patterns
Reduced training time
More reliable output

This leads to better product quality and improved customer satisfaction.

Why this matters for manufacturers considering palletizing automation

This case highlights how robotic palletizing improves:

Production throughput
Labor efficiency
Workplace safety
Operational consistency

Most importantly, the results are measurable and repeatable.

Conclusion: a fast, scalable path to higher performance

TIDI Products achieved:

30% productivity gains immediately
Continued improvements with each new deployment
Safer, more efficient operations

Their advice is simple: Automate sooner to unlock results faster.

For manufacturers dealing with labor shortages, production bottlenecks, or safety concerns, palletizing automation offers a clear path to improvement.