How Elite Robots CP Series Palletizer transformed TurboGrün Production Line

In the lawn-care industry, efficiency and reliability are critical for meeting seasonal demand. TurboGrün, a well-known manufacturer of long-term lawn fertilizer based in Baden-Württemberg, Germany, faced a growing challenge: heavy 20-kg bags, fluctuating staffing levels, and production bottlenecks that threatened throughput and delivery reliability. To stay competitive and ensure stable production, the company needed a palletizing solution that was both powerful and flexible.

The Challenge: Heavy Loads, High Turnover, and Increasing Complexity

TurboGrün’s production line required continuous handling of 20-kg fertilizer bags—a physically demanding task that contributed to high employee turnover and inconsistent staffing. Additionally, the company needed a way to switch quickly between various bag sizes and pallet configurations without complex programming or long setup times.

In short, the goals were clear:

• Reduce ergonomic strain on employees
  
• Eliminate bottlenecks caused by manual palletizing
  
• Increase throughput and production reliability
  
• Enable fast, flexible adjustment for different packaging formats

‍Leveraging the intuitive programming inherent to Elite Robots, the combined system setup is remarkably simple. Operators define routes and inspection points directly through QRobot's graphical interface, using live camera feedback. The cobot by Elite Robots enables quick, real-time adjustments to its positions, facilitating rapid adaptation to diverse cable types and component layouts.

The Solution: Three Elite Robots CP Series Palletizers

TurboGrün has implemented three Elite Robots CP series palletizing solutions, combining three CPL-07 bases (with lifting column) with three CS625 cobots, all equipped with Hanvac vacuum grippers. These systems were distributed across multiple production lines and seamlessly integrated into the existing conveyor and warehouse management infrastructure (WMS/ERP).

A key component of the success was the software which empowered the whole system, Elite Robots' proprietary palletizing wizard, thanks to which:

• Packing patterns could be created without any programming knowledge
  
• Each layer could be defined individually
  
• Operators could adjust palletizing layouts within minutes
  
• Mixed pallets and variable bag sizes were supported natively
  

Despite the sophistication of the technology, the systems were fully commissioned by the on-site service team within just one week.

The Result: Higher Productivity and ROI in Under One Year

The impact was immediate and measurable:

• 35–40% increase in throughput
  
• Significantly reduced physical strain on employees
  
• Fast return on investment—under 12 months
  
• High flexibility for different bag formats and pallet types
  
• Optimal utilization of cobots through quick pattern adjustments
  

By automating the most physically demanding part of the production process, TurboGrün was able to stabilize staffing needs, improve reliability, and boost overall plant productivity.

Conclusion: A Showcase for Rapid, High-Impact Automation

The TurboGrün project demonstrates how quickly modern cobot technology can be integrated into real-world production. Within a single week, the company transformed a major bottleneck into a competitive advantage. Thanks to Elite Robots’ intuitive software, modular hardware, and targeted service support, TurboGrün now operates with higher efficiency, greater flexibility, and a healthier workforce—all with an ROI realized in under one year.

‍