Blog : How to build an end-of-line solution that scales with your speed.
WRAP / STACK / TRACK
Here’s a simple framework for building end-of-line systems that keep pace today and scale tomorrow.
For most manufacturers, the filler gets all the attention.
But the end-of-line is where the value is actually banked – or lost.
It’s also where things get messy: Mixed SKUs, late changeovers, limited labour, forklift traffic, retailer compliance and traceability.
If the end-of-line can’t keep up, OEE suffers no matter how good the upstream assets are.
At Foodmach, we use a simple framework to design end-of-line systems that work today and scale tomorrow:
STACK – Present and palletise product efficiently
WRAP – Stabilise loads to spec with minimum film
TRACK – Identify every pallet with compliant, usable data
STACK/WRAP/TRACK
Three words for three essential functions:
- Destack by presenting pallets, layer sheets and consumables without manual lifting or forklift congestio and stack by palletising fast and accurately in any pattern or SKU mix
- Wrap by stabilising loads to specification with the least film and highest repeatability
- Track by identifying every pallet with compliant labels and live data
The magic happens when these are designed as one integrated system, not a collection of separate machines.
Below is how STACK / WRAP / TRACK plays out across our portfolio – from flexible low-speed cells to high-throughput lines – and how Lease2Buy Finance can make getting there a lot easier.
STACK: Smarter ways to move product onto pallets
Depalletising: getting product into the line cleanly
A high-performance end-of-line starts with a reliable infeed.
Foodmach’s reputation in depalletisers is second to none, particularly in beverage and FMCG, where gentle handling and uptime are critical.
Gentle depalletisers:
- Feed cans, bottles or cartons into the line at consistent rates
- Protect packaging integrity for lightweight materials
- Minimise operator intervention and manual handling
- Integrate with line control, vision and coding systems
By stabilising the infeed, downstream palletising becomes far more predictable and OEE is easier to sustain.
Mobile cobots and compact robot cells: Instant Palletiser
For many plants, the first step away from manual pallet building is a compact robotic cell.
Foodmach’s Instant Palletiser and mobile cobot/robot solutions are designed to:
- Drop into tight footprints without major civil works
- Handle palletising for one or more lines
- Support quick recipe changes for different SKUs and patterns
- Be relocated as production priorities change
These cells are ideal for seasonal products, new formats and growth lines.
They eliminate repetitive lifting, reduce ergonomic risk, and deliver consistent pallet quality without the complexity of a large engineered system.
Layer palletiser with integrated stretch wrapping: Robopac PALWRAPP
As volume grows and space becomes tight, a layer palletiser with integrated stretch wrapping comes into its own.
A compact combination like this:
- Forms full layers at speed, including mosaics and mixed SKUs
- Compresses and squares each layer for stability
- Wraps the load in the same footprint, in cycle with the palletiser
- Reduces the need for long pallet conveyors and extra guarding
The result is “big line” performance in a small space, ideal for manufacturers who want to increase throughput without expanding the building.
Pick & place systems: Precision for small packs and mixed SKU work
Pick & place solutions are used where:
- Smaller or more delicate packs need gentle handling
- Mixed SKU displays or promotional pallets are built
- Cases, trays or shrinkpacks must be oriented in specific ways
Robotic pick & place cells combine vision, end-of-arm tooling and smart software to create consistent patterns that would be slow and error-prone to build manually.
High-speed palletising: Robomatrix
At the high end, Robomatrix® is Foodmach’s flagship palletiser family for demanding applications.
Robomatrix systems:
- Handle up to high-speed case rates with layer-forming or multi-infeed layouts
- Manage single SKU, rainbow and multi-SKU promotional pallets
- Support fast changeovers through recipe-driven patterns
- Offer robust tooling and clamping for heavy trays or lightweight corrugate
For high-volume beverage and FMCG, Robomatrix is the engine that allows the end-of-line to match the filler.
WRAP: Stabilising loads with less film and less risk
A good pallet is only as good as its wrapping.
Under-wrapped pallets fail containment tests and damage product, while over-wrapped pallets waste film and money.
Foodmach’s wrapping solutions are built around the right combination of mechanics, controls and film technology.
Semi-automatic stretch wrapping
Semi-automatic turntable or rotary arm wrappers are ideal for:
- Lower volume lines and mixed SKU operations
- Sites transitioning from hand wrapping
- Situations where operators are already moving pallets with pallet jacks or forklifts
Programmed wrapping cycles control pre-stretch, overlap and top sheets, so the same containment you would expect from an automatic machine is delivered with minimal film and minimal operator training.
Fully automatic stretch wrapping
As volume and labour constraints increase, fully automatic wrapping becomes the logical step.
Foodmach integrates:
- Turntable wrappers for moderate speeds and compact footprints
- Rotary arm wrappers where high speeds or unstable loads are present
- Ring-style wrappers for very high throughput and continuous operation
- Robotic stretch wrappers for maximum flexibility around multiple lines or warehouse positions
Across all styles, the goals are the same:
- Match wrapper speed to palletiser output
- Bake containment standards into recipes by SKU
- Measure and control film usage to reduce consumable costs
- Minimise manual touches and forklift movements around the wrapper
Whether as stand-alone machines or part of a fully integrated STACK / WRAP / TRACK architecture, these systems help keep pallets safe, compliant and cost-effective.
TRACK: Making every pallet visible and compliant
Pallets that can’t be scanned, traced or matched to orders cost time and money.
TRACK is about turning each pallet into a reliable data point in the supply chain.
SSCC pallet labelling
An effective TRACK strategy starts with SSCC pallet labels that:
- Are generated to GS1 standards
- Are applied automatically in the right position
- Scan first time at despatch, warehouse and retail DCs
Foodmach integrates pallet labelling into the end of line so labels are created, printed, applied and verified in the same flow that builds and wraps the pallet.
This reduces manual labelling, rework and chargebacks and supports EDI (Electronic Data Interchange) messaging to trading partners.
QR codes and digital engagement
Beyond SSCC, QR codes are increasingly used for:
- Consumer engagement and promotions
- Digital product passports
- Extended traceability and provenance data
By treating QR as part of the coding and marking strategy – not an afterthought – manufacturers can link physical pallets and packs to rich digital information without complicating line operation.
Coding & Marking with Markem-Imaje
Foodmach is a long-term integrator of Markem-Imaje coding and marking systems, including the CoLOS® software platform.
Markem-Imaje solutions provide:
- Reliable printing of dates, batch codes and variable data on packs, cases and pallets
- Centralised message design and management through CoLOS
- Integration to ERP, MES and WMS systems so data is consistent from product to pallet
- Full support for GS1 barcodes, 2D codes and customer-specific requirements
Because coding is tied into the same control layer as STACK and WRAP, product, case and pallet records stay aligned, which simplifies recalls, quality investigations and customer audits.
Labelling systems: Rotary and inline
For many SKUs, labelling is as critical as coding.
Foodmach supplies and integrates:
- Rotary labellers for high-speed beverage and food applications
- Inline labellers for flexible packaging, cases and pallets
These systems are specified and integrated so that artwork changes, SKU switches and promotional labels can be managed without jeopardising uptime or label placement accuracy.
Making the numbers work: Lease2Buy Finance
All of this capability only delivers value once it is on the floor and running.
Capital budgets, however, do not always move as fast as operational needs.
Foodmach’s Lease2Buy Finance is designed to:
- Turn large capital outlays into predictable monthly operating costs
- Align payments with the savings generated by improved OEE and reduced labour
- Make it easier to stage projects, starting with critical bottlenecks
- Preserve cash for core business investments while still modernising the end of line
For many manufacturers, Lease2Buy is the practical bridge between recognising the need for STACK / WRAP / TRACK integration and actually implementing it.
Where to next?
Whether the current challenge is manual pallet building, inconsistent wrapping, retailer chargebacks or traceability gaps, the path forward starts with a clear look at STACK, WRAP and TRACK as one system.
Foodmach’s team can help map the current state, identify the real constraint and design a staged roadmap – from compact Instant Palletiser cells to high-speed Robomatrix lines with fully automatic wrapping and integrated SSCC labelling, coding and data.
The goal is simple: bank more of the value created upstream, with an end-of-line that is safer, faster and ready for whatever the market throws at it next.
