Jacobi Robotics Mixed-Case Palletizing Solutions | FORTNA

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Solutions: Mixed-Case Palletizing

Mixed-case palletizing by Jacobi Robotics, powered by FORTNA

FORTNA has partnered with Jacobi Robotics to bring AI-powered mixed-case palletizing to distribution and fulfillment operations. For decades, building stable, store-ready pallets from a live, unsequenced case flow has been one of the most labor-intensive and hardest-to-automate workflows in the warehouse.

The Jacobi OmniPalletizer changes that. Powered by FORTNA’s operational design expertise and integrated with FORTNA WES™, it installs directly into existing conveyor lanes, handles any case mix without upstream sequencing infrastructure, and proves its performance in a digital twin before any capital is committed.

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Mixed-case solution with FORTNA operational design

Begin your mixed case palletizing project with FORTNA Operational Design to convert case-level picking into a downstream-ready, transport-efficient unit load that compresses labor, time and cost across the network while improving service levels.

Learn more about FORTNA Operational Design.

Benefits of mixed-case palletizing solution for your existing warehouse

No redesign. No sequencing. No guesswork.

Brownfield-ready: The OmniPalletizer installs as a modular robotic cell into existing conveyor lanes and dock areas with no new sequencing infrastructure or extended shutdowns.
Handles any case flow: From live, unsequenced pick-to-belt waves to floor-loaded receiving docks, the system accepts cases in whatever order they arrive and builds stable, rule-compliant pallets across unlimited SKUs.
Performance proven before deployment: FORTNA and Jacobi validate every deployment in advance using a digital twin running the customer’s actual SKU history and order mix.
Reduces labor dependency: Mixed-case pallet building is one of the most physically demanding roles in the warehouse. Automating it removes a chronic source of musculoskeletal injury, improves retention, and delivers consistent output around the clock.
Native Integration with FORTNA WES™: OmniPalletizer connects directly to FORTNA’s warehouse execution software giving operations teams unified visibility and control.

How OmniPalletizer works

Cases arrive live and unsequenced

The system observes each incoming case in real time with no reliance on pre-sorted or buffered flow

AI-driven decision making

The OmniPalletizer reasons about stack stability, weight distribution, crushability, and business rules on every single placement

Physics-aware motion planning

Robot trajectories are computed and validated in the digital twin before execution, so the system behaves identically in simulation and on the floor

Resilient to real-world variability

Adapts continuously to SKU changes, packaging variation, and shifting order profiles without manual reprogramming

Simple operator experience

An intuitive HMI surfaces exceptions with clear step-by-step instructions; operator training time is under one day

The FORTNA difference

The FORTNA data-driven, consultative approach sets us apart by turning operational data into actionable insights that drive measurable results. We don’t just recommend solutions—we analyze your unique operational metrics, workflows and demand patterns to identify the most impactful opportunities for improvement. Our consultative process combines advanced analytics with robust supply chain expertise to design strategies tailored specifically to your facility needs, whether that is optimizing throughput, improving labor efficiency or increasing storage utilization. This fact-based methodology ensures decisions are grounded in evidence, not assumptions, delivering long-term value and a clear return on investment for your warehouse operations.

FORTNA Distribution Optimization Framework Lifecycle Performance Services supports a diverse portfolio of MHE and software implementations worldwide

FORTNA Framework

FORTNA can help optimize business-critical operations with the FORTNA Framework™

The FORTNA Distribution Optimization Framework^TM (FORTNA Framework) leverages proprietary processes, tools, and algorithms to design and deliver solutions using best-fit automation technologies and intelligent software.

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FORTNA's experience enables us to develop solutions for industry-unique challenges and cross-pollinate best-in-class strategies and solutions.

Our industry expertise

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FAQs

Mixed-case palletizing is the process of building a
single pallet from many different products—varying in
size, weight, and fragility—in whatever order they arrive.
Unlike single-SKU palletizing, the system must make
real-time stacking decisions that satisfy weight
distribution, crush limits, aisle sequencing, and height
constraints simultaneously.

No. OmniPalletizer cells install into existing conveyor
lanes without major facility modification and coexist
with manual stations during ramp-up. There is no
requirement for upstream sequencing infrastructure or
building redesign.

The customer’s actual SKU data and historical order
mix are run through a proprietary digital-twin
simulation. This produces throughput, pallet quality,
peak-day performance, and ROI projections based on
real operating conditions. The same AI engine that runs
in simulation runs in production, so results are
consistent from proof-of-concept through go-live.

OmniPalletizer is configured to enforce each
customer’s operational rules—aisle-friendly store
sequencing, temperature-zone grouping, pharma
compliance, stop-based routing, carrier requirements—
and validates them in simulation before deployment.

Traditional systems rely on large upstream buffers to
feed cases in a predetermined order, costing tens of
millions and taking 12–18 months to build.

OmniPalletizer uses AI to plan placements from live,
unsequenced flow, delivering comparable pallet quality
with a fraction of the infrastructure and deployment
timelines measured in weeks.