Overview

A propane tank manufacturing client approached MJ Engineering to design and install a fully automated robotic cell for palletizing 20- and 30-pound propane tanks. Previously, operators manually stacked tanks onto a motorized lift conveyor—a repetitive and labor-intensive process. The client’s goal was to automate this operation to increase throughput, reduce manual handling, and ensure each pallet was built to customer specifications before being wrapped and prepared for shipment.

Our Solution

MJ Engineering developed a custom robotic palletizing cell integrated with a pallet dispenser and wrapping station to create a seamless, fully automated system. The End of Arm Tool (EOAT) was engineered to handle tanks, tier sheets, and pallets using an automatic tool changer, allowing the system to manage both boxed and unboxed tanks.

The cell design was created in SolidWorks© to align with the client’s floor plan and production requirements. Additional support included programming and controls integration for the conveyor and pallet dispensing systems. The robot— a FANUC© M410/140iB—manages the complete pallet-building process, picking and placing pallets, tanks, and tier sheets to create stable, ready-to-ship loads.

Outcome

The new robotic cell delivers consistent, high-speed palletizing performance that exceeds what was possible through manual labor. It reduces operator handling, enhances safety, and ensures precision with tolerances as tight as ±0.2 mm. The automated cell can palletize both 20- and 30-pound propane tanks, boxed or unboxed, using a single multi-purpose EOAT design. Pre-ship runoff testing at MJ Engineering verified full system performance before installation at the client’s facility.