Simplify Used Pallet Sorting with the PSS Pallet Sorting System

Pallet sorting line for efficient used pallet processing

Pallet sorting line for automated and efficient sorting of used pallets

With the pallet sorting line from Pallet Sorting Systems (PSS), the heavy manual work is taken out of the sorting process. Manual sorting, stacking and grading are replaced by an automated, predictable flow where one sorting operator and one forklift driver can process up to 600 pallets per hour.

LECARO currently holds the following performance records:

• 766 pallets/hour for de-stacking Euro pallets

• 600+ pallets/hour for sorting Euro pallets

• 500+ pallets/hour for sorting industrial pallets

The pallet sorting line handles infeed, singulation (one-by-one separation) and stacking. Operators no longer lift heavy pallets and work at a safe distance from forklift traffic. This ensures an ergonomic and safe working environment with a stable, continuous material flow.

PSS pallet sorting lines process mixed pallet streams without mechanical adjustments. Common pallet formats such as Euro pallets, block pallets (light, medium, heavy) and GMA pallets are automatically graded, sorted, and stacked by type and/or quality.

Key operational benefits:

• fast processing of mixed and unsorted pallet loads;

• up to 50% fewer forklift movements → lower internal transport costs;

• ergonomic and safe working conditions without heavy lifting;

• consistent, sale-ready sorted pallet stacks.

Sorting by type, quality and defects

Efficient sorting of mixed used pallets

Used pallets often arrive mixed in type, dimension and condition. The automated pallet sorting system from PSS handles this mixed flow continuously, without changeovers. The system sorts pallets by type, quality grade and visible defects, building clean, uniform stacks for each category.

With just one operator, pallets are graded consistently—by quality (A/B/C), by type, or both.

For companies requiring maximum uniformity and independence from operator experience, AI4Pallets automatically identifies pallets, groups them, and directs each pallet to the correct stacker. This increases speed and ensures consistent quality.

The pallet sorting line can be used for:

• Euro pallet grading (A/B/C);

• high-speed pallet de-stacking / pallet nesting;

• UK standard and industrial pallet sorting by type, quality or payload;

• CP pallet sorting (CP3, CP4, CP5, CP7, CP8, CP9);

• Sorting GMA 40×48 inch.

Sorting performance between 350 and 600 pallets per hour depends on pallet quality, required sorting detail, and—most importantly—the teamwork between the sorting operator and the forklift driver.

Business results:

• shorter throughput times;

• fewer sorting errors;

• clean, sale-ready pallet flows;

• better use of manpower and equipment.

Circular processing, legislation & safety

Pallet sorting line as the foundation for circular pallet processing

Re-using pallets plays a significant role in the circular economy. European legislation such as Directive 94/62/EC requires companies to reduce packaging waste and promote reuse. With the pallet sorting line and the optional PSS pallet repair line, companies can meet these requirements by re-using pallets in a controlled and efficient manner.

For pallets that are not economical to repair, PSS offers the next step in circular processing: the
PSS Robotic Pallet Saw System. This system dismantles pallets fully automatically and recovers boards and blocks for direct reuse in the repair line. This maximises material efficiency and minimises waste.

On ergonomics and safety, the pallet sorting line offers clear advantages. Operators no longer work close to forklift traffic, and the automated infeed/outfeed reduces forklift movements by up to 50%. This reduces risks and creates a clean, predictable working environment.

All PSS sorting lines comply with NEN-ISO 11228-1:2003, the European standard for lifting and handling. The 18-kg continuous lifting limit is fully taken over by the machine, protecting employees from physical strain.

Results for your organisation:

• higher productivity through fewer manual steps;

• a safe, organised workplace with reduced internal transport;

• compliance with EU regulations and ergonomic standards;

• full support for circular pallet processing using PSS modules.

Pallet Sorting Systems – Modular. Reliable. Efficient.