Flex Stack Pro: Scalable Palletizing System Targets Industry Labor Challenges

The Flex Stack Pro, developed by Codi Manufacturing and featuring Festo automation technologies, represents a comprehensive approach to palletizing automation designed to address mounting labor challenges in consumer packaged goods (CPG) and third-party logistics (3PL) operations.

According to Mark Walters of Festo, the collaboration around this product emerged when Codi Manufacturing approached Festo about expanding its product portfolio to include palletizing systems. The result is the Flex Stack Pro, a fully integrated Festo automation system.

A central component of the Flex Stack Pro is Festo’s FPaKit, which Festo refers to as being as close to a gantry palletizer in a box as possible. FPaKits include pre-set, sized and assembled axes and motors, multi-protocol servo drives, hybrid controller with pre-installed palletizing software, cables, software license and user interface.

In addition to the FPaKit’s features, the Flex Stack Pro also uses Festo’s vacuum gripping technology and backplane-speed CPX-AP-A remote digital I/O.

The Flex Stack Pro is available in three payload capacities: 20 kg, 30 kg and 50 kg. Customers can choose between single or double palletizer configurations, with options for depalletizing and slip sheet removal. Codi Manufacturing said it plans to offer tier sheets with glue options for the Flex Stack Pro in the near future.

Festo’s new palletizing software is also installed on the Flex Stack Pro. It features a choice of web browser interface (Chrome, Edge or Firefox) and a one-click auto-generate function to calculate optimal pack patterns. Automatic plausibility and limit-value checks are built in to ensure the pack pattern is functional. With this software, users gain a 3D view of the pallet that can be rotated and zoomed for visual checks. Packaged goods can be repositioned using a mouse. This software also ensures operators are aware of necessary interventions and monitors and records the status of the palletizing process.

Scalability as a core feature

One of the system's distinguishing characteristics is its scalability within the same machine footprint. 

“Operations processing five packs per minute can run on single-phase 110/120V power using a standard wall socket. As production demands increase to 10 packs per minute with heavier loads up to 90 pounds, the same platform scales to three-phase power without requiring additional floor space,” said Walters.

Flex Stack units can be skid-mounted and moved via pallet jack or forklift, said Jared Jones, chief operating officer at Codi Manufacturing. 

Users also have the option of using the new Festo AX Motion Insights Electric and Pneumatic subscription-based predictive analytics apps to increase uptime and throughput while lowering inventory. 

“For high-speed operations, knowing what components are doing in real time is invaluable for planned preventive maintenance in order to avoid interrupting production,” Jones said. “Customers can order motors, drives and cylinders before they fail so they don't have to stock them in inventory.” 

Addressing the labor crisis in industry

The driving force behind the Flex Stack Pro's development is the growing automation imperative in manufacturing and logistics. Rising labor costs, increasing workers' compensation expenses and attendance reliability issues are pushing companies toward automated systems, said Walters.

"If an employee doesn't show up, that affects your operations. This machine shows up every day," he added.

The system is designed to perform tasks traditionally requiring manual labor, such as stacking and unstacking pallets. This eliminates injury risks while ensuring consistent operational capacity.

The video below, captured at Pack Expo 2025, show the Flex Pack Pro in action.

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