The Winner
Stacks It All.

Get more out of every pallet –
with CanButler full-layer palletizing

With the CanButler, you can palletize monoblock cans and bottles fully automatically in gap-free layers. Full-layer palletizing makes optimal use of the pallet while also improving the utilization of the available cargo space in the truck. Depending on the can type, this allows significantly more products to be transported per trip, in certain applications even more than 15,000 additional cans per truck.

In combination with the upstream CanLab can inspection machine, this creates a continuous, fully automated process in which only flawless products are palletized. We would be happy to calculate the overall impact this solution can achieve in your operation together with you.

Experience the CanButler

External video (Vimeo)

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The video shows the CanButler in operation: cans are automatically brought together into a pallet-sized formation, picked up, and placed precisely onto the pallet.

Compared to conventional bundle palletizing, this creates gap-free palletizing that uses the available space much more efficiently. Watch the machine process step by step and gain detailed insight into how our technology works.

Application example 1

Beverage bottle: Ø59mm, L190mm

The larger the can diameter, the greater the impact: for formats where fewer cans fit on a pallet in general, gap-free use of the pallet surface makes the decisive difference. With full-layer palletizing, around 16.3% more cans can be palletized per pallet.

beverage_bottle_59mm_top_view — Full-layer palletizing vs. bundle palletizing, top view

beverage_bottle_59mm_side_view — Full-layer palletizing vs. bundle palletizing, side view

All benefits at a glance

15'334 (16.3%) more

cans per truck
120 fewer

truck trips per year, per production line
600 fewer

truck trips per year, with five production lines
€122,760 less

transportation costs per year, per production line
€612,777 less

transportation costs per year, with five production lines

The difference in numbers

*The calculation is based on industry-standard benchmarks for production and transportation. Actual values may vary depending on the manufacturer.

	Bundle palletizing	Full-layer palletizing	Difference (full-layer − bundle)
Cans per pallet	2'772	3'223	451 more, +16.3%
Cans per truck	94'248	109'582	15,334 more, +16.3%
Trucks per year (per production line)	856	736	120 fewer
Trucks per year (with 5 production lines)	4'280	3'680	600 fewer
Transportation costs per year (per production line, range: low/high €/km)	€753'280 to 875'688	€647'680 to 752'928	€105'600 to 122'760 less
Transportation costs per year (with 5 production lines, range: low/high €/km	€3'765'520 to 4'377'417	€3'238'400 to 3'764'640	€527'120 to 612'777 less
Transportation	Higher transportation frequency	Reduced transportation
Environment	Higher CO₂ emissions	Reduced CO₂ emissions

Application example 2

Cosmetic can: Ø45mm, L185mm

Full-layer palletizing also pays off for smaller can diameters. Although smaller formats can already be packed more densely on the pallet, gap-free use of the pallet surface still creates a noticeable additional effect. In the 45mm example, full-layer palletizing allows around 9.2% more cans to be palletized per pallet.

cosmetic_bottle_45mm_top_view — Full-layer palletizing vs. bundle palletizing, top view

cosmetic_bottle_45mm_side_view — Full-layer palletizing vs. bundle palletizing, side view

All benefits at a glance

15'334 (9.2%) more

cans per truck
41 fewer

truck trips per year, per production line
205 fewer

truck trips per year, with five production lines
€41,943 less

transportation costs per year, per production line
€210,738 less

transportation costs per year, with five production lines

The difference in numbers

*The calculation is based on industry-standard benchmarks for production and transportation. Actual values may vary depending on the manufacturer.

	Bundle palletizing	Full-layer palletizing	Difference (full-layer − bundle)
Cans per pallet	4'884	5'335	451 more, +9.2%
Cans per truck	166'056	181'390	15,334 more, +9.2%
Trucks per year (per production line)	486	445	41 fewer
Trucks per year (with 5 production lines)	2'430	2'225	205 fewer
Transportation costs per year (per production line, range: low/high €/km)	€427,680 to 497,178	€391,600 to 455,235	€36,080 to 41,943 less
Transportation costs per year (with 5 production lines, range: low/high €/km	€2,137,520 to 2,484,867	€1,956,240 to 2,274,129	€181,280 to 210,738 less
Transportation	Higher transportation frequency	Reduced transportation
Environment	Higher CO₂ emissions	Reduced CO₂ emissions

PRACTICAL BENEFITS

More Advantages

Beyond improving pallet and truck utilization, full-layer palletizing offers clear advantages over bundle palletizing in day-to-day production. Here are the key benefits at a glance:

Less manual handling

Automated inspection and palletizing reduce the need for manual checks and stacking.
Ideal for thin-wall and lightweight cans

Deep-drawn WB-DWI cans from 0.16 to 0.20µm and lightweight cans from 0.22 to 0.25µm can no longer be bundled reliably. Strapping can leave pressure marks or even damage the cans. Full-layer palletizing eliminates this stress point.
Reduced transport damage

Bundle packaging creates additional risks, such as pressure inside the bundle or straps shifting during transport. Full-layer palletizing helps prevent these typical causes of damage.
Greater tolerance for shape variations

Full-layer palletizing is more forgiving when cans show minor shape deviations, such as elephant foot. Bundling, by contrast, can lead to dents more quickly.
A cleaner production process

Fewer manual interventions mean fewer touchpoints, resulting in a cleaner and more reliable production flow.
Consistent pallet quality

Automated stacking creates repeatable, straight, and stable pallet patterns. Manual palletizing naturally leads to more variation.
Quality assurance with CanLab

When combined with CanLab, every can is inspected inline. At the same time, valuable data is generated for traceability and production analysis, helping improve reject handling and root cause analysis.
Fast return on investment

In many cases, the payback period in Europe is around 2.5 to 3 years, depending on line output, transportation costs, and labor costs. We calculate the actual impact based on your specific production data.

Inspection

Quality inspection
with the CanLab

With the upstream CanLab can inspection machine, full-layer palletizing becomes a continuous, fully automated process. Every can is inspected inline, and even the smallest deviations are reliably detected before the products reach the pallet. The result: only flawless cans for your customers, without manual visual inspection and without any additional effort in your operation.

Seamless integration into your line

The visualization shows the optimal material flow from the finished, empty can or bottle to the palletized unit. CanLab and CanButler work seamlessly together, creating a continuous, efficient process, from inline quality inspection to full-layer palletizing for optimal use of the transport area.