Palletising & Load Handling Protection

Palletising zones have become some of the most complex and high-risk areas in today’s warehouses. Here, automation and human activity converge at speed. As automation scales, so do the risks. That’s why safety must be built into the process from the very beginning.

Risks in palletising

Palletising systems, whether robotic or fixed, operate with high speed and force. But they don’t exist in isolation. Goods constantly move in and out, and employees often enter for inspections, packaging or troubleshooting. These interventions create real risk.

To protect both people and productivity, here are the key risks to be aware of:

Entering active zones exposes workers to fast-moving arms, grippers and conveyors
Undefined entrances increase the risk of accidental access during inspections or troubleshooting
Unstable loads and open layouts create exposure during picking, unloading or label checks
In crossover areas, forklifts, AGVs, AMRs and operators often interact without clear separation
Transitions between robots, conveyors or restart sequences can leave zones briefly unprotected

Axelent helps you protect against these risks by providing guarding, zoning and access control solutions that align with your real-world flow.

We help secure active zones, define safe entry points, separate pedestrian and vehicle traffic, and ensure transitions and restart sequences remain protected. Our modular systems adapt to layout changes and support compliance from day one. At the same time, they help keep your material flow safe and efficient.

How Axelent protects your process

We divide palletising safety into two categories, each with its own challenges and priorities.

Robotic arms palletising cartons inside safeguarded automation cell

Palletising Robotics

In automated warehouses, robotic palletising often happens in shared spaces with people and mobile equipment. These environments demand flexibility and high throughput, but they also bring a unique set of safety challenges. Axelent delivers guarding that moves with the process. Our systems ensure safe human-robot interaction, adapt to workflow shifts and maintain safety in compact, high-traffic zones.

Protect palletising robotics

Automated palletising line with robotic arms and pallets in safety zone

Palletising Systems

Fixed palletising and depalletising lines are built for speed and precision, often running with minimal human presence. But when maintenance or troubleshooting is needed, the safety margin disappears. Axelent provides guarding that defines access, secures the perimeter and keeps the line running safely without slowing production.

Protect palletising and depalletising

Safety that follows the flow

Palletising safety isn’t just about fencing off a robot. It’s about protecting the entire process. Risk increases where goods are transferred between systems or people interact with automation.

Effective safety covers the entire zone:

Entry and exit points
Conveyor handoff areas
Buffer areas and crossings

Axelent helps you identify and protect each of these points for safer, smoother flow.

Robotic palletiser stacking large bags with machine guarding for operator safety

Automated industrial robot arm operating in a factory with conveyor systems and safety fencing

Prevent palletiser downtime

Palletising is one of the few areas where high force, speed and human interaction meet. It’s also one of the few where a single incident can halt the entire process.

Protection here isn’t just about meeting regulations. It’s about keeping the line running, supporting safe workflows, and managing risk. Axelent designs safety systems that contain high impact forces, support flow and fit both high-speed lines and space-efficient setups.

By building safety into the process from the start, we help prevent unplanned stops. Our modular systems adapt to layout changes and support compliance from day one. The result is fewer disruptions, safer operation and better control of time and cost.

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Plan for compliance from the start

When safety is added late, it often leads to redesigns, delays and documentation issues. Axelent helps you build compliance into your process from day one, using safety systems developed in line with the Machinery Directive/Regulation, OSHA regulations and safety standards such as ISO 12100, ANSI B11.0, B11.19, CSA Z432 and numerous generic safety standards.

For palletising environments that include robotics, we also support compliance with EN ISO 10218-1 and 10218-2 as well as ANSI RIA R15.06. These standards cover the safety requirements for industrial and collaborative robots. Our solutions help you meet them through smart zoning, guarding and risk-adapted layouts that align with your process from day one.

We provide machine guarding, impact protection, doors and locks. Each part is designed to support compliance and adapt to the real conditions of your layout.

From guarding distances and access control to restart sequences and human access planning, we help you create safe environments that are easier to validate without compromising flow or flexibility.

Do you want to go deeper?

Explore Axelent’s full safety guide

Safeguard more than the robot itself

In many warehouses, goods move straight from the palletiser or de-palletiser to conveyors, sorters or AMRs. The risk doesn’t end with the robot.

Axelent helps you:

Maintain safety through transitions
Protect handoff zones and crossings
Create a unified safety setup across zones

Industrial robotic palletiser and depalletiser handling goods on conveyor line

Get in touch with us

Do you have any questions about warehouse automation safety? Do you want to discuss your project or get tailored advice? Our safety specialists are here to guide you every step of the way. Axelent helps you create safety that works in sync with your robotics. Send us your layout and we’ll help you design a solution that protects your people without slowing down the process.

Sebastian Jiteg

Global Sales

Project Manager

+46 (0)370-37 37 42

Show email address

+46 (0)370-37 37 42

Russell Harris

Global Sales

Global Account Director

+44 79 57 56 65 69

Show email address

+44 79 57 56 65 69

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