Industrial manufacturers often struggle with capacity, labor strain, and consistency.
At Korea Filter Engineering, manual palletizing of 10–20 kg (22-44 lb) industrial filter boxes was limiting output, increasing ergonomic risk, and slowing deliveries.
After deploying the Robotiq PE20 with a UR20, the company achieved:
30% production increase
50% reduction in worker fatigue
Near 50% reduction in injury-related absences
Zero workplace incidents since installation
ROI expected within 2 years
This case study shows how collaborative robot palletizing improves productivity while protecting workers in heavy-load manufacturing environments.
Company overview: Industrial filter manufacturing in South Korea
Founded in 1996 and based in Gimpo, Korea Filter Engineering manufactures industrial filters used in electrical discharge machining (EDM).
Industry: Industrial filter manufacturing
Employees: 15
Daily palletizing load (before automation): ~4 tons
Box weight: 10–20 kg
With a lean workforce and growing demand, manual palletizing became a production bottleneck.
The challenge: Manual palletizing of heavy boxes
Before automation, workers manually lifted and stacked approximately 4 tons of product per day.
Key issues included:
1. Ergonomic risk and worker fatigue
Repetitive lifting of 20 kg boxes
Back, shoulder, and muscle strain
Aging workforce increasing injury risk
Fatigue affecting morale and consistency
2. Productivity limitations
Daily output capped at 200 boxes
Delays caused by physical strain and absenteeism
Difficulty maintaining consistent throughput
3. Failed alternatives
Previous lifting aids were tested but operations repeatedly reverted to fully manual palletizing due to complexity or inefficiency.
The company needed a solution that was:
Compact
Stable
Easy to operate
Safe for human-robot collaboration
Quick to deploy
The solution: Robotiq Lean Palletizing
In early 2025, Korea Filter Engineering selected the Robotiq PE20 palletizer integrated with the UR20 collaborative robot.
Why this palletizing system?
Handles boxes up to 20 kg
Supports up to 20 SKUs
Maximum pallet height: 2130 mm (84 in)
Compact footprint for space-constrained facilities
Works alongside employees without extensive safety fencing
Intuitive interface requiring minimal training
Fast deployment timeline
Early 2025: Evaluation
March 2025: Quotation
May 2025: Installation and launch
Minimal layout changes were required. The system integrated seamlessly with the existing conveyor.
Operators were able to learn and run the system within minutes, reducing dependency on specialized robotics expertise.
Results: Measurable gains in productivity and safety
1. 30% production increase
Output increased from 200 to 250 boxes per day
Higher throughput without increasing headcount
Improved delivery reliability
2. Improved worker health and safety
Injury-related absences nearly halved
Worker fatigue reduced by more than 50%
Zero workplace incidents since installation
Young-Hun Yoo, Assistant Manager in Production, shared:
“After using the robot, our bodies are healthier, and we feel less tired—less than half compared to before. We have more energy left for our families after work.”
3. Workforce optimization
One full-time employee reassigned to higher-value tasks
Less physical strain, more operational focus
Stronger team morale
4. Strong financial case
Expected return on investment within 2 years
Reduced indirect costs related to injury and absenteeism
Increased capacity without expanding facility space
Why collaborative robot palletizing works in heavy manufacturing
This project demonstrates key advantages of cobot palletizing systems:
Protects workers from repetitive heavy lifting
Removing 4 tons of daily manual lifting dramatically reduces ergonomic risk.
Increases output without expanding workforce
Automation supplements labor instead of replacing it.
Scales with product variability
The PE20 handles up to 20 SKUs, supporting diverse product lines.
Fits in space-constrained facilities
Compact design makes it viable for small and mid-sized manufacturers.
Enables fast ROI
Measurable productivity and safety improvements accelerate payback.
Woo-Seok Kim, Director of Business, explained the decision:
“We checked many robot systems, but the PE20 was the most stable. Protecting our workers is the most important thing, and the PE20 allows us to do that. That is why it is worth the investment.”
Key takeaways for manufacturers considering automation
If your operation involves:
Manual palletizing of heavy boxes
Repetitive lifting causing fatigue or injuries
Labor shortages or aging workforce challenges
Limited floor space
Productivity plateaus due to physical constraints
Collaborative palletizing automation may deliver rapid, measurable impact.
Korea Filter Engineering’s transformation proves that manufacturers do not have to choose between:
Productivity and safety
Growth and workforce wellbeing
Automation and operational stability
With the right palletizing solution, you can achieve all three.
Is Lean Palletizing the right fit for your production line?
Use Robotiq’s Palletizing Fit Tool to quickly assess whether cobot palletizing makes sense for your operation and what a realistic deployment could look like for your facility. You’ll even get personalized estimates for ROI and payback periods and a 3D simulation of what Lean Palletizing could look like on your factory floor.
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