Proven Approach to Mixed Case Depalletization

The Plus One Depalletization System can handle a variety of pallets, helping increase flexibility and speed as compared to manual operations. Importantly, the Plus One Robotics Depalletization System is especially effective with mixed pallets featuring multiple package types, as well as rainbow pallets consisting of a single product type with known dimensions. Users find a reduction in picking and sorting times by approximately 30%, which in turn can reduce the costs associated with these operations.

For a demonstration or to find out more on how we can boost your mixed depalletization operations, contact the Plus One team here.

Download the Automated Depalletizing Brochure

Watch these videos to see Plus One’s Depal Solution in action

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Mixed Pallet

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Random Mixed Robotic Depalletization with PickOne

Mixed Case Depalletization Capabilities

Layer-by-Layer Picking
Fully depopulates the top layer of the pallet before going to the next layer to prevent toppling.

Item Classification
Classifies items by package type to dynamically adjust grip strategy, acceleration/deceleration, speed, and change path or end effector.

Empty Pallet Detection
Confirms an empty pallet so that the system can replace the empty pallet with a full one.

Place Verification
Images the place zone to confirm that only a single case was placed to prevent double induction.

Offset Picking
If the item to be picked is smaller than the robot end effector, an offset is automatically calculated for the pick to prevent damage to adjacent items on the pallet.

Supported Item Types
Boxes, overwrapped trays, cartons, bags

Supported Edge Cases
Homogeneous layers of flat black cases, cases with alternating color on the flaps, banded cases, cases with highly reflective tape, cases with gaps

Pick Command Processing Speed
350ms - 480ms typical

Typical Pick Rates
350 - 700 picks per hour

The Depalletization

To meet consumer demand across e-commerce, food and beverage or distribution operations, the number of product SKUs is continually increasing, resulting in an ever-expanding variety of pallet load patterns. This is a challenge to both manual and automated solutions as today’s depalletization solutions must be able to move pallets that are a mix of dissimilar products in different colors, shapes, dimensions, weights and packaging. Correctly sorting and placing the contents of these mixed pallets can be common bottlenecks for operations, and thus, a negative impact on productivity and profitability.

Rainbow/Row Pallets:

Rainbow depalletization refers to the process of handling different rows of homogenous layers of any single product type. Each layer can vary widely in shape, size, weight, etc.

Mixed Case Pallets:

Mixed case pallets add complexity to the depalletization process, as each layer on the pallet may contain a combination of products, sizes and shapes with absolutely no uniformity.

Mixed Case Palletizing is quickly growing to be a normal part of palletizing operations as it allows a company to ship a variety of SKUs for individual orders that may not warrant a full pallet load. The variety of packaging in these pallets typically poses a unique challenge to automation.

The Solution: Power Your Operations with Robotic Depalletization

Although flexible depalletizing has been challenging for robots of the past, today’s advances in artificial intelligence and vision software have changed the game. The artificial intelligence capabilities of PickOne software enable a robot to identify different objects on the pallet based on their shape, size, and weight. This allows for seamless handling of delicate or irregularly shaped items that would traditionally pose challenges for manual laborers or conventional machinery. Moreover, these robots can also adapt their grip strategy according to each item's specific requirements, ensuring damage-free handling throughout the depalletization process.

The Plus One Depalletizing System extends the power of the PickOne software for mixed automated depalletizing applications through image scanning and analysis, while being supported by Yonder, Plus One’s unique Human-in-the-Loop capability for handling exceptions. This boosts the efficiency and productivity of robotic depalletization, minimizing errors while reducing labor costs and potential ergonomic issues, enabling 24/7 operations.

These systems can be configured to handle almost any pallet, packaging or product mix in warehouses across diverse sectors.

How AI-Powered Robotic Depalletization Works

Pallets are brought to the robotic depalletizer/Pick Station by either human workers or a pallet conveyor. In fully automated environments, the pallet is scanned, and product information sent to the warehouse management system to keep track of inventory.

The PickOne Perception Kit images the pallet. The software then analyzes the 2-D, 3-D, and AI data to identify each pickable item in the pallet and assigns each one an associated confidence level.

PickOne sends the robot controller an array of pick locations and poses for each pickable item via the PickOne API.

For items with low confidence levels the software automatically generates a Human-in-the-loop(HITL) request by calling in remote human intervention. With a response time of under six seconds, these robot managers efficiently handle exceptions such as reflective packages or unfamiliar shapes by simply selecting an item in the scene to be picked. In seconds, our Human-in-the-loop (HITL) updates PickOne, and PickOne sends the data to the robot.

In parallel, Human-in-the-loop (HITL) stores the robot manager’s responses, enabling the machine-learning algorithms to make the system smarter as it works. This ensures continuously increasing performance over time.

Items are transferred onto an outfeed conveyor,sorter, or specialized equipment like a descrambler that separates and positions them for subsequent processes like storage, further processing, or fulfilling outbound orders.


  • Increase throughput by as much as 30% for the breakdown of mixed pallets
  • Ensure high uptime with the ability to handle exceptions
  • Reduce repetitive and non-rewarding tasks, upskilling labor to positions that lead to higher work satisfaction and retention
  • Reduce the number of picking errors
  • Achieve consistent and accurate flow of goods
  • Adaptable in real-time to deal with changes in packaging and damaged goods


  • Number of full-time positions in current depalletizing operations
  • Incoming warehouse volumes
  • Case unloading rates/hour requirements
  • Size, weight, and variety of items on the pallets
  • Available footprint and utilities
  • Other equipment that may need to interface with depalletizing system


  • Agriculture & Feed
  • General Merchandise
  • Grocery (non-perishable)
  • Maintenance & Repair Operations (MRO) Supplies
  • Medical Supplies
  • Retail

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Automated Depalletizing