Programmable load forming systems, components thereof, and methods of use are disclosed. In one aspect, a
programmable load forming
system is programmed to perform the method of downloading a calculated path from the computer to the
robot controller, moving one or more bundles along the calculated path to position the one or more bundles in a predetermined stacking position of a stacking pattern using the
robot, and determining if the
robot has completed moving along the calculated path. The calculated path is defined, in part, by the stacking pattern and other parameters such as, for example, bundle geometry, bundle levelness, bundle
compressibility, among other parameters. In another aspect, the
system is programmed to perform a method of sensing the top of a bundle and controllably placing a bundle. Additional aspects are directed to systems and methods of safely operating the robot and an inventive hopper design for holding bottom / tie sheets.