Abstract This paper discusses the design and development of a physical simulator for robotic palletization. The design is aimed at two objectives. One, to provide a test bed for studying issues relating to automation of palletization and second, to provide a teaching tool for some common elements of material handling automation. The major hardware components of the system are an IBM 7545 robot, a Personal Computer, an Allen-Bradley Programmable Logic Controller (PLC), Conveyors and a Bar Code Reader. The software components include the IBM AML 4.1 language, PLC Software and BASIC software for the BASIC Module of the PLC.