As automated warehouse solutions are typically focused on movement and storage, one labour-intensive manual task is overlooked: pallet unwrapping. Introducing the VARO Pallet Unwrapper, which automates this repetitive and ergonomically challenging manual task.
The unwrapping process begins as a pallet enters the system, either as a standalone unit or integrated within an existing production line. Designed to accommodate standard pallet formats (including EUR EPAL and US sizes up to 1200 x 1200 mm) and heights of up to 2.7 metres, the system is built with flexibility in mind. The system is also capable of handling irregularly shaped or unevenly stacked pallets, automatically adapting to their contours without the need for pre-programming.
Once positioned, the machine initiates a controlled cutting sequence. Rather than relying on blunt force or manual slicing, the stretch film is precisely and gently cut, ensuring that the goods beneath remain undamaged. This is particularly relevant for unstable or irregularly stacked loads, where traditional manual methods can introduce risk. The pallet is first measured with millimetre precision, allowing the cutting mechanism to follow the exact shape of the load for consistent and accurate results.
Following the cut, the system proceeds to fully remove the stretch film automatically, eliminating the need for human intervention. In more advanced configurations, such as the “Unwrapper Control,” the machine can also handle top covers, caps and securing strips, extending automation beyond basic side wrapping. The removed film can be simultaneously extracted via an optional suction-based system, where it is transported, separated and prepared for recycling or reuse, supporting more sustainable operations.
Stabilisation and handling of complex loads
A notable feature of the system is its ability to manage unstable palletised goods. In configurations designed for complex loads—such as bottles, drums, or loosely stacked containers—the machine incorporates enclosing sides that stabilise the pallet before and during film removal. This ensures that products do not shift or collapse once the tension of the wrap is released.
Additionally, the system can correct minor inconsistencies in pallet stacking, effectively preparing loads for downstream processes. This stabilisation step is critical in automated environments where variability in incoming pallets can disrupt flow.
Importantly, the ongoing safety issue of pallet stack integrity is mitigated as much as possible as staff can stand back, or indeed continue working in other areas while the risk point of releasing stretch film tension is taken care of by the VARO system.
For enhanced performance, an optional AI-based add-on is available, capable of detecting abnormalities in pallet structure or wrapping and adjusting the process accordingly to maintain stability and efficiency. Data, therefore, is also available.
Integration and throughput
The VARO Unwrapper is designed for continuous, multi-shift operation, supporting high-capacity logistics environments. Its compact footprint allows it to function either as a standalone unit or as part of a larger automated line, positioned before or after other processes such as depalletizing.
Typical process times average around 60 seconds per pallet, depending on load characteristics such as height, shape and film type, enabling consistent and predictable throughput.
For operations seeking further automation, the system can be paired with an integrated robotic cell, enabling goods to be handled individually or layer-by-layer immediately after unwrapping. This creates a seamless transition from inbound pallet handling to downstream processing.
In high-volume environments, the system is capable of processing up to hundreds or even thousands of pallets per day, supporting round-the-clock operation without interruption.
Safety, efficiency and operational impact
From an operational standpoint, the system addresses three key concerns:
- Safety: by removing manual cutting, the risk of workplace injury is significantly reduced.
- Product integrity: controlled cutting and stabilisation minimise the chance of damaging goods.
- Efficiency: automation eliminates a labour-intensive step, improving throughput and consistency.
Additionally, the system reduces repetitive and ergonomically challenging manual tasks, contributing to improved working conditions and lower long-term labour costs.
Environmental performance is also improved, as extracted stretch film can be immediately collected, compacted, and directed into recycling streams, reducing waste and supporting sustainability targets.
These benefits are particularly relevant in facilities handling large volumes of pallets daily, where even small inefficiencies can scale rapidly.
Closing the automation gap
While much of warehouse automation has focused on movement and storage, pallet unwrapping has remained an unaddressed gap. Systems like the VARO Unwrapper demonstrate how targeted innovation in a single process step can contribute to broader operational gains.
By combining precise cutting, automated removal, and load stabilisation, the technology reframes unwrapping as a controlled, repeatable process rather than a manual necessity. In doing so, it aligns this final stage of inbound handling with the wider trajectory of warehouse automation.
Furthermore, VARO offers multiple system configurations—such as Cut, Core, and Control—allowing businesses to select a solution tailored to their specific operational complexity and load stability requirements.
