Block One Pallet Factory
Complete End-to-End Robotic Warehouse Automation
The Pallet Factory is Block One’s fully integrated system—combining storage, picking, replenishment, and palletizing into a fully autonomous, high-redundancy solution built for beverage distribution.
Proven, Stable & Scalable
Additional robots create system redundancy to prevent downtime and ensure consistent output. As SKU counts grow and picking becomes more complex, robots can be added to expand capacity and balance workload across multiple stations—keeping operations running smoothly at any scale.
Trusted by Distributors
automation in action
Pallet Factory Built of Four Core Modules
The Pallet Factory runs on three integrated modules that automate the warehouse from end to end. RoboArm handles high-volume palletization for low-SKU products. ACR stages B SKUs near RoboArm to reduce travel time. ACR with dense case storage automates handling and retrieval of C SKUs. VNA robotic fork lifts manage high-density pallet storage and replenishment. Smart AI software guides modules to optimize storage, sortation and palletization.
RoboArm Palletizer with AMRs
ACR – Autonomous Case-handling Robot
Robo Pallet Storage and Retrieval System
AI Software – Designed for DSD
We Make Productivity Predictable
Automation that brings order to the chaos with modular robotic automation built to solve the labor crisis and eliminate complexity.
- Works from day one – No downtime, no disruption
- Reduces labor dependency – Automates the backbreaking work
- Affordable – RoboArm Module starts at 350k installed and integrated with your ERP
What Distributors Are Saying
The Path to Always-On, Lights-Out Automation
Most distributors start with RoboArm, then expand by adding modules and additional robots over time. As each layer is added, The Pallet Factory evolves — from targeted automation to a fully autonomous, 24/7 operation.
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Powered by PREDICTABILITY
Your Warehouse, Without Guesswork
We take the heavy lifting out of heavy lifting. No more worrying about labor shortages, picking errors, or delays.
• No more labor risk – Robots don’t quit, call in sick, or slow down.
• No more costly mistakes – Software catches human errors before they impact operations.
• No more wasted time – Consistent, scalable output, every shift, every case.
"Don’t just build a better warehouse. Build a better business."
Understand autoamtion
You should begin implementing modules as soon as possible. If you’re on the sidelines you’re losing your ability to scale with demand and new SKUs. Labor is a problem, seasonality is a problem, raising SKU count is a problem, storage is a problem. All these can be solved with the Block One Pallet Factory™.
Installation can be as fast as three weeks for our RoboArm palletizing module.
Implementations for our first module are $350K installed & ERP-integrated. Add more modules to handle more SKUs and complexity.
Goods-to-Robot means products are retrieved by robots and delivered directly to robots for palletization. Instead of human workers or conveyors bringing cases to a person, the entire process is automated.
Traditionally, warehouse workers walked the aisles, pulling products from different addresses and stacking pallets as they went. This process is slow, labor-heavy, and inefficient compared to optimized robotic systems.
Goods-to-Robot reduces floor congestion, removes wasted travel, optimizes routing through AI, and eliminates manual labor from palletization—saving time, money, and space.
AI powered smart software detects issues (damaged case, location mismatch) and self-corrects (reassigns, reroutes, resequences) without halting the flow.
curated hardware for dsd
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Easily find parts, printers, scanners, and hardware accessories from Block One and our partners like Zebra Technologies