1200 cans per minute: KUKA robots palletize pet food cans in Poland

Demand for pet food is rising. Manufacturers need to expand their capacity and automate their production. At a Polish pet food manufacturer, KUKA robots help place pet food cans on conveyor belts before and after sterilization. This allows 1,200 cans per minute to be fed through the production system.

December 4, 2025

Innovation in focus: Clevertech and KUKA automate the pet food industry

The Italian company Clevertech is one of the leading providers in the field of end-of-line packaging. Its robot-based solutions are mainly used in the pet food industry. This industry is developing particularly dynamically. That’s why more than 80% of Clevertech systems rely on KUKA robots. “The ‘humanization’ of pet food – for example through yogurt, smoothies or vegetable mixes – poses new requirements for packaging,” explains Luca Carollo, Business Developer at Clevertech. “Precise, gentle and fast processes are needed – robotics is indispensable here.”

“Every empty space in a layer means wasted energy”

In addition to product geometry, the customer also faced challenges in optimizing energy efficiency. To achieve this, it must be ensured that the cans are assembled into layers which are complete and stable. When the layers are complete and stable, heat transfer becomes more uniform and efficient, as more mass (the cans) absorbs the energy and less energy is lost. After sterilization, the challenge shifted: the now wet and thermally stressed cans must be unloaded without introducing moisture into the system.

KUKA robots transport 1,200 cans per minute onto the conveyor belt © KUKA Group

Automation supports the dynamics of the pet food industry

“In the pet food market, we are seeing a shift toward more compact packaging formats – similar to what we once saw in the beverage sector,” explains Luca Carollo. The current solution processes up to 1,200 cans per minute – with room for even higher speeds. The core element is a patented gripping system that combines vacuum technology with mechanical thrust. The Hybrid Sweep-off Technology enables seamless movement of the layers and precise control during compression.

By preserving the intermediate layers - stabilizing layers between product stacks - material waste and replacement costs are reduced. “And every warped intermediate layer means replacement costs. This system helps the customer remain efficient and sustainable,” adds Luca Carollo. With over 98% operational efficiency and a scalable design, the solution is not only fast – it is built for long-term performance and replicability across multiple sites.

Ready for what’s next: From pouches to mobile palletizing cells

The versatility of the solution from Clevertech and KUKA is already evident in further applications: In Romania, a similar robot-supported setup is used for handling pet food pouches – the product characteristics there require particularly sensitive processes. “The principle remains the same: KUKA for loading, KUKA for unloading – one robot handles the product, the other handle consumables as interlayer and pallet,” explains Luca Carollo. “We are presenting this new solution international trade shows,” Carollo adds.