Caspari Paletten Chooses Another Hybrid PSS Sorting System

Pallet sorting line number two will soon be delivered to Caspari Paletten by Pallet Sorting Systems. The new installation is intended for the company’s facility in Herne, Germany, and combines automatic sorting of common pallet types with robot-controlled processing of less frequently occurring pallet sizes.

With this follow-up investment, Caspari Paletten has once again chosen the PSS hybrid concept. The combination of a pallet sorting and repair line and a robotic module makes it possible to process both high-volume and smaller pallet flows efficiently within one installation.

Second Pallet sorting line for the Herne facility

The new installation will be equipped with two integrated repair stations and five automatic stackers. These stackers will process the most common pallet types, including:

• Euro pallets;
• industrial pallets;
• CHEP pallets;
• LPR pallets;
• IPP pallets.

The operator assesses each pallet according to type, quality and possible damage. Using the control system, the operator determines whether the pallet is transported to one of the automatic stackers, a repair station or the robotic module.

This creates a controlled pallet flow in which every pallet is immediately directed to the correct destination.

Robotic module for special pallet sizes

Less common pallet types can occupy unnecessary space when a dedicated automatic stacker must be reserved for each type. The robotic module provides a flexible solution.

Pallets with special dimensions or a lower sorting frequency are directed to the robotic section by the operator. The robot automatically picks the pallets from the conveyor and sorts them across six different stacking positions.

This keeps the five standard stackers available for the highest-volume pallet types, while smaller and less common pallet flows can also be processed automatically.

Sorting and repairing in one installation

The Pallet sorting line in Herne combines sorting, repair and robot-controlled stacking within one process. Pallets identified as damaged during inspection are automatically transported to one of the two repair stations.

Thanks to the side infeed, repair workers receive only pallets that actually require repair. After repair, the pallets can be returned to the central pallet flow and transported to the correct stacking position.

This working method prevents duplicate inspections and reduces the number of manual pallet movements.

Benefits of the hybrid sorting system

The combination of automatic stackers, repair stations and a robotic module provides Caspari Paletten with several advantages:

• one operator can sort more than 500 pallets per hour;
• five automatic stackers process the most common pallet types;
• the robot sorts special pallets across six additional positions;
• damaged pallets are sent directly to the repair stations;
• employees do not need to lift or move pallets manually;
• forklift movements around the sorting process are significantly reduced;
• different pallet sizes can be processed within one installation;
• the modular design provides options for future expansion.

Ergonomic and safe working conditions

The automatic infeed and discharge of pallets reduce the physical strain on both the operator and the repair workers. Employees work from fixed positions and do not need to carry or manually stack pallets.

Forklift traffic around the workstations is also reduced. This creates a safe, well-organised and consistent working process.

SCADA reporting and PSS App

The control system of the Pallet sorting line records the most important production data. Caspari Paletten receives a daily CSV report containing information on sorted and repaired pallets.

The reports provide insight into:

• the total number of processed pallets;
• quantities per pallet type and sorting position;
• the number of repaired pallets;
• production output per employee;
• working hours and achieved output.

Using the PSS App, Caspari Paletten can monitor the current performance of both the sorting line and the robotic module live. This data supports production planning, cost control and further process optimisation.

A proven concept for a second facility

With this second hybrid sorting system, Caspari Paletten is also introducing the PSS concept at its Herne facility. The combination of human quality control, automatic processing and flexible robotic sorting provides high capacity and consistent sorting quality.

Pallet Sorting Systems is proud that Caspari Paletten has once again chosen a PSS solution. We look forward to the production, installation and commissioning of this second Pallet sorting line.

Would you like to learn more about the automatic sorting and repair of pallets? View our solutions for pallet sorting and pallet repair.

Pallet Sorting Systems – Modular. Reliable. Efficient.