Flevo Pallets Chooses Efficient and Measurable Sorting

Pallet sorting line with eight automatic stackers for Flevo Pallets, this installation from Pallet Sorting Systems transforms pallet sorting into an efficient, structured and fully measurable process. Two of the eight stackers can also automatically nest pallets.

The machine is designed to sort up to approximately 3,000 pallets per working day with a fixed team of one operator and one forklift driver. The pallets are assessed according to type, quality and possible damage.

Pallet sorting line with eight stackers

Pallets are placed on the infeed conveyor in stacks of up to eighteen. The stacks are then automatically transported to the pallet tipper and fed individually to the inspection position.

At this central position, the operator assesses each pallet. Good pallets are automatically transported to the correct stacker. Pallets requiring repair are collected separately in one designated stacker.

The Pallet sorting line has eight stacking positions, two of which are suitable for the automatic nesting of pallets. This allows Flevo Pallets to efficiently process different pallet types and quality grades without manually moving or stacking individual pallets.

Fixed staffing and a clear operating process

The installation is operated by one operator and one forklift driver. The operator is responsible for assessing the pallets, while the forklift driver supplies unsorted pallets and removes the completed stacks.

This clear division of tasks provides:

• clearly defined responsibilities;
• fewer unnecessary pallet movements;
• a consistent operating process;
• less forklift traffic around the operator;
• stable sorting quality throughout the working day.

Because one operator makes all sorting decisions, the pallets are consistently assessed according to the same criteria. This contributes to uniform and reliable quality across the sorted pallet flows.

Sorting capacity of 400 to 550 pallets per hour

Depending on the incoming pallet mix, quality and number of sorting criteria, the installation can process approximately 400 to 550 pallets per hour.

With one operator and one forklift driver, Flevo Pallets can sort up to approximately 3,000 pallets per working day. The central inspection position and automatic discharge ensure a continuous pallet flow without unnecessary waiting times.

Benefits for the operator

The Pallet sorting line supports a safe and ergonomic working method. The operator works from one fixed inspection position and does not need to lift or stack pallets manually.

The main benefits include:

• a fixed and well-organised workstation;
• clear sorting decisions;
• no manual lifting or stacking of pallets;
• no direct forklift traffic around the operator;
• a continuous and controlled pallet flow;
• reduced physical strain during the sorting process.

Benefits for Flevo Pallets

The new installation provides Flevo Pallets with a structured and measurable sorting process. The automated system delivers both operational and financial benefits:

• a stable sorting output of approximately 400 to 550 pallets per hour;
• up to approximately 3,000 sorted pallets per working day;
• approximately 50% fewer forklift movements around the sorting process;
• lower labour costs per sorted pallet;
• consistent and uniform sorting quality;
• automatic separation of pallets requiring repair;
• clear insight into production volumes and performance.

SCADA reporting and real-time monitoring

The installation is equipped with SCADA technology, which automatically records important production data.

Flevo Pallets gains insight into:

• the total number of sorted pallets;
• quantities per pallet type and sorting category;
• distribution across the different stackers;
• production per hour and per day;
• operational data from the installation.

Daily reports are provided in CSV format. These files can be used in the office for further analysis, production planning and process optimisation.

The current status of the Pallet sorting line can also be monitored live through the PSS App.

The result at Flevo Pallets

With the PSS installation, Flevo Pallets has a stable, efficient and measurable sorting process. One operator makes all sorting decisions, while the machine handles the internal transport and automatic stacking.

This results in a consistent output of approximately 400 to 550 pallets per hour, depending on the pallet mix and quality. At the same time, the number of forklift movements, physical strain and cost per sorted pallet are significantly reduced.

PSS Pallet sorting lines

PSS Pallet sorting lines are now in operation at more than 150 customers throughout Europe. The machines are used to sort different pallet formats, including Euro pallets, block pallets and industrial pallets. The machines are also equipped for the automatic nesting and de-nesting of pallets.

The combination of high sorting speed, robust machine construction, low maintenance requirements and efficient online service makes the PSS Pallet sorting line a proven solution for professional pallet companies.

Pallet Sorting Systems – Modular. Reliable. Efficient.