Stacking 80 lb bags of premix concrete all day is demanding work. To reduce the dependence on manual palletizing labor, a concrete and mortar mix producer added a custom ABB robotic bag palletizing system to its existing packaging line. The same robot stacks filled bags, places empty wooden pallets, and lays a paper slip sheet on each pallet before starting the next load.
This installation shows how automated bag palletizing can fit an existing operation and offer a practical path to lower labor requirements.
Adding Automation to an Existing Bagging Line
The company packages several types of concrete and mortar mix in open mouth poly-woven bags. Its existing open mouth bagging machine and bag sewing system remained in place, with the new palletizing equipment added downstream.
Space at the end of the line was limited, so the system was custom designed to fit a compact footprint. The layout brings together bag preparation conveyors, the ABB robot, nearby pallet and slip sheet stacks, and powered conveyors for stacking and discharging completed pallets.
How the Bags Are Prepared and Stacked
After sewing, the upright bags travel along the existing V-belt conveyor and transfer onto a short flat belt conveyor feeding a bag kicker.
The kicker pushes the bottom of each bag out, laying it flat with its label facing up. The bag then travels onto a settling conveyor, where square rollers help distribute and settle the concrete mix. Guides straighten the bag before it reaches the robot’s bag pick conveyor.
This preparation helps present each bag to the robot in a consistent position. The ABB robot grips the bag with its end-of-arm tool, moves it over the pallet, and places it in a preset stacking pattern.
Once the pallet is full, powered rollers move it onto a full pallet accumulation conveyor. A forklift operator retrieves the load and takes it to a separate stretch wrapper before moving it to shipping or storage.
One Robot Handles Bags, Empty Pallets, and Slip Sheets
The robot also prepares the next pallet for stacking. Its multi-function tool handles three jobs in sequence.
1. Place an Empty Pallet
The pallet gripping mechanism extends to pick up a wooden shipping pallet from a nearby stack and place it onto the palletizing conveyor. Squaring guides align the pallet for bag placement and later discharge.
2. Add a Slip Sheet
The pallet gripping mechanism retracts, and the robot uses suction cups to lift a thick paper slip sheet from a separate stack and place it on the pallet.
3. Resume Bag Stacking
The suction cups retract, and the bag gripper is ready to begin the next preset stacking pattern.
Automating these preparation steps reduces the manual work required between completed loads, as well as the heavy lifting involved in stacking the bags themselves.
Touchscreen Controls and Remote Support
An intuitive touchscreen interface gives operators a straightforward way to run the system. An internet connection allows remote troubleshooting and software updates when needed.
Installation and operator training typically take a couple of days for systems of this type, with the schedule depending on site readiness and the work required to connect to the existing line.
What Does an ABB Bag Palletizing System Cost?
For customized industrial automation and robotic integration similar to this installation in mid-2026, Tinsley’s current budget range is approximately $215,000 – $250,000, depending on the configuration and project requirements and freight costs. Installation, start up, and training services vary and cost around $15,000 – $25,000 depending on the final size and complexity of the system.
That price range reflects a configured palletizing system, rather than the robot arm alone. This installation combines bag handling conveyors, a multifunction robot tool, automatic pallet and slip sheet placement, pallet conveyors, touchscreen controls, programming, software licensing, and safety fencing.
Note: When budgeting a project, confirm the equipment scope and whether freight, installation, and any site preparation are included in the quoted price.
Estimated Labor Savings and Payback
For this type of application, the automated system could replace the equivalent of three to four full-time positions devoted to bag stacking and pallet preparation. At an example annual labor cost of $50,000 per position, including benefits, the potential labor savings are shown in the table below.
| Labor equivalent | Potential annual labor savings | Simple payback on $215,000 |
| Three full-time positions | $150,000 | About 17 months |
| Four full-time positions | $200,000 | About 13 months |
These estimates assume the full labor cost is eliminated or avoided. They are a simple payback illustration, not measured results, and exclude ongoing operating and maintenance costs and any project costs outside the base $215,000 figure. If employees are reassigned, the benefit is added capacity elsewhere rather than the same reduction in payroll.
Another major expected benefit is reducing the repeated hiring and training associated with a physically demanding job. Automated stacking also supports a more consistent pace at the end of the packaging line.
Planning a Bag Palletizing System?
Tinsley Equipment Company can help evaluate a robotic palletizing system for your existing or new bagging line.
Contact us with your bag weights and dimensions, required bags per minute, pallet size, and available floor space to discuss a configuration for your operation.
Ask a question -or- Get a Price Quote
Call: (979) 217-1480