Combined system

General benefit: integrated system

Pallet Sorting Line and Repair Line: One Integrated System for Maximum Efficiency

The pallet sorting line and repair line from Pallet Sorting Systems (PSS) form a fully integrated workflow in which sorting and repairing used pallets operate as one continuous process. The sorting operator makes the quality decision for the entire line: good pallets are stacked immediately by type and grade, while repairable pallets are automatically routed to the repair section.

Repair technicians receive only pallets that actually require repair, ensuring a clean and efficient workflow with no misfeeds or incorrect choices. The automated infeed and outfeed create a stable material flow, reduce human error, and improve overall processing speed.

This combined system works seamlessly with AI4Pallets, the MultiSorter, and the Robotic Pallet Saw System for pallets that are no longer economically feasible to repair—forming a complete circular pallet-processing platform.

Employee benefits: safety, ergonomics, workflow

Ergonomic, Safe and Predictable Work for Sorting Operators and Repair Technicians

The integrated pallet sorting line and repair line significantly improves workplace ergonomics.
Repair technicians receive pallets on an upper conveyor, directly at working height. Heavy lifting, bending and long walking distances disappear from the process. Technicians can work faster, safer and more consistently.

The sorting operator works at a safe distance from forklifts and focuses on a clear task: removing plastic, labels, film and making the quality decision. This removes uncertainty and eliminates inconsistent grading between employees.

Employee benefits:

• no heavy lifting or manual pallet handling

• safe workstations away from forklift traffic

• predictable workflow with no unnecessary movement

• fully compliant with EN-ISO 11228-1:2003 lifting and handling standards

This ergonomic approach increases stability on the shop floor and boosts repair performance.

Company benefits: output, cost savings, data

Higher Output, Lower Costs and Full Process Control

The combined pallet sorting line and repair line delivers measurable business advantages.

✔ Up to 35% increase in repair output

Repair technicians work only on pallets that require repairs — no misrouting, no time lost handling good pallets.

✔ Up to 50% fewer forklift movements

Only full stacks are delivered to the sorting line, and only sale-ready stacks are removed.
This drastically reduces internal transport costs and safety risks.

✔ Higher pallet value through better grading

Only one sorting operator makes all quality decisions, preventing inconsistencies.
AI4Pallets can automate grading for maximum accuracy.

✔ Complete data logging via PSS SCADA

Daily CSV reports include:

• pallets repaired per workstation

• total sorted volumes

• quality grades

• working hours

• pallet flows (good, repair, reject)

✔ Fully circular pallet workflow

Pallets that cannot be repaired economically are routed to the Robotic Pallet Saw System for automatic dismantling, recovering blocks and boards for reuse.

The result:
lower labour costs, higher throughput, safer workflows and a consistently higher pallet value.

Pallet Sorting Systems – Modular. Reliable. Efficient.