7 tons per shift: Halloren lightens the load with the Smart Palletizer
Why Nick Hartig chose the Smart Palletizer
“We’ve been able to protect our employees’ health and sustain rapid growth over the past five years thanks to the Smart Palletizer. I would recommend it to anyone looking for a reliable collaborative palletizing solution.”
The challenge
Before automating their palletizing process at their end of line, Halloren’s employees were manually lifting and stacking up to 2,500 cartons, roughly 7 tons of boxes, per shift. According to Nick Hartig, “The constant heavy lifting left our employees exhausted. Sick leaves rose, and pressure to find labor increased – it simply wasn’t sustainable.”
Over time, this repetitive and physically demanding work took a toll on the production team. It also raised concerns about the sustainability of the process as production volumes grew. What Halloren needed was a reliable, high-throughput palletizing solution that was simple for existing staff to operate without requiring any programming knowledge.
The search begins
In 2020, Halloren began searching for a reliable palletizing solution that could handle their products with ease and take the load off their employees. Their criteria for a solution were straightforward: a dependable robot, strong service support in case of any issues, and a quick return on investment.
After comparing several palletizing solutions, Halloren found the Smart Palletizer to be the most suitable option – checking off every requirement on their list. What stood out most to them was the ability to get a robust palletizing system, including installation and service, at a fraction of the cost of other options. That’s when Halloren decided to move forward with the installation.
Implementation and service
Although the Smart Palletizer was installed before Mr. Hartig joined Halloren, he proudly confirms that the installation went smoothly and that commissioning was completed faster than expected. The system has been running reliably ever since. Today, it efficiently processes around 7 tons of cartons per shift, and thanks to an annual service contract with Smart Robotics, it remains fully up to date — both in software and hardware.
Smart Palletizer
Results that Stack Up
1 Increased employee wellbeing:
Nick Hartig says the greatest benefit of automation has been the physical relief for employees: “When psychology students visited our facility in Halle, they were concerned that the robot was taking away human jobs. However, our employees assured them that the Smart Palletizer is a blessing for their physical and mental well-being, not a curse.”
2 Consistent, reliable performance:
Nick Hartig was happy to share that the system runs reliably and has become an integral part of the production line. In the rare instance that troubleshooting is required, issues can be resolved quickly, either by Halloren’s own team or remotely with support from Smart Robotics’ service engineers. This reliability provides peace of mind for both Mr. Hartig and the operators working alongside the robot.
3 Return on investment achieved:
Thanks to the reduction in physical strain and sick leave, along with labor savings and improved operational continuity, the return on investment was achieved rather quickly, far exceeding the Halloren team’s expectations.
Conclusion
Nick Hartig was happy to share that the Smart Palletizer has fully met his expectations, delivering reliable performance and tangible value on the factory floor.
The Smart Palletizer has enabled Halloren to:
– Support rapid growth while reducing the physical strain on employees
– Maintain consistent palletizing performance across shifts
– Lay the groundwork for further end-of-line automation
The collaboration between Halloren and Smart Robotics stands as a strong example of how automation can enhance both employee well-being and operational efficiency, all while driving sustainable growth for the business.
About Halloren
Halloren is Germany’s oldest chocolate manufacturer, producing and packaging sweet treats at high volumes. Founded in 1804, Halloren is known for its signature Halloren-Kugeln and a wide range of confectionery products enjoyed across Europe. Combining tradition with innovation, the company continues to modernize its production while preserving the craftsmanship that has defined the brand for over two centuries.
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