Royal Containers of Brampton, ON, developed a pioneering box hopper prefeeder robot, the first of its kind, to enhance the efficiency and safety of our high-speed folder-gluer operations. This innovative system addresses significant ergonomic hazards by eliminating the need for manual lifting of 7,000 to 9,000 pounds of cartons per hour, thus preventing repetitive strain injuries and allowing operators to be reassigned to other tasks. The robot mitigates mechanical hazards by operating within a fully fenced cell equipped with safety curtains and interlocks, ensuring operator safety from moving parts of the robotic arm. The development took 18 months and involved sophisticated adaptations, mainly designing a splitter assembly to handle heavy stacks without damage, ensuring high-quality standards. The robot has increased throughput from 13,500 to 15,000 cartons, reducing human error with a fault detection system that prevents jams, maintains consistent production speeds, and enhances overall efficiency.