Caspari Paletten chooses hybrid sorting system with robotic support

Caspari Paletten chooses hybrid sorting system with robotic support

1. Machine description

Caspari Paletten has invested in a standard pallet sorting and repair line from Pallet Sorting Systems (PSS).
The line includes two repair workstations and five stackers for sorting the most common pallet types, such as Euro pallets, industrial pallets, and pool pallets including Chep, LPR, and IPP.

To further increase efficiency, the installation is expanded with a robot module that processes less common pallets with non-standard dimensions.
The operator directs pallets either to the stackers or to the robot positions, where the robot automatically sorts them into six stacking positions.
This hybrid sorting line combines manual sorting and repair with automated robotic processing, providing maximum flexibility and a continuous pallet flow.

2. Benefits for operators and pallet repairers

The working environment at Caspari Paletten is designed with focus on ergonomics, safety, and efficiency.

• Reduced physical effort through automatic pallet infeed and outfeed.

• Improved safety due to 50% fewer forklift movements and a separated pallet flow.

• No need to lift or carry pallets, resulting in lighter and more efficient work.

• The side infeed ensures that repairers only receive pallets that actually require repair.

3. Benefits for the company

Caspari Paletten achieves measurable performance improvements with this configuration:

• One sorting operator can process over 500 pallets per hour.

• Higher output per employee without additional labor.

• Consistent pallet quality through the combination of automatic sorting and manual repair.

• Shorter lead times thanks to automatic handling of non-standard pallets by the robot.

• Flexible expansion through the modular setup of the system.

• Real-time performance insights and cost control via the PSS Scada System and PSS App.

4. Efficiency and monitoring

Through the PSS Scada System, Caspari Paletten receives a daily CSV report containing all sorting and repair data per operator.
Using the PSS App, the company can monitor live performance worldwide.
The data provide insights into production volumes, pallet quality, working hours, and overall output — supporting process optimization, maintenance planning, and cost management.

5. Result

By combining manual repair, automated sorting, and robot-assisted pallet handling, Caspari Paletten operates a modular and efficient hybrid system.
The line unites low physical strain, operator safety, and high processing capacity – exactly what Caspari Paletten aimed for.

Learn more about pallet automation:
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