Pallet sorting line for The Pallet Company – installed November

Pallet sorting line for The Pallet Company – installed November

The Pallet Company has invested in a pallet sorting line from Pallet Sorting Systems (PSS), designed to process mixed pallet streams at high speed with just one sorting operator and one forklift driver.
The system was installed and taken into operation in November, after a selection process based on efficiency, pallet flexibility and the ability to handle both European and North-American pallet types.

The new pallet sorting line is configured with twelve automatic stackers, enabling The Pallet Company to sort a wide range of pallet types at high throughput, while ensuring stable output and consistent quality.

What the pallet sorting line means for The Pallet Company

The pallet sorting line automates the full process from de-stacking, grading and type selection to automated stacking.
This gives The Pallet Company a streamlined pallet flow with predictable performance and minimal manual intervention.

Key operational benefits:

• Sorting of Euro pallets, light/medium/heavy Block pallets, and GMA 48×40 inch pallets
• Ability to nest open-block pallets, improving logistics efficiency
• One sorter makes all decisions → consistent output and fewer errors
• One forklift driver handles only full stacks → far fewer forklift movements
• Clean, sale-ready stacks produced directly from the line
• SCADA + CSV reporting for daily performance insights

The system is modular and can be expanded in the future with a pallet repair line, a MultiSorter robot system, or the Robotic Pallet Saw System.

Advantages for the sorting operator

The sorter now works with a controlled, ergonomic and predictable workflow:

• Pallets are presented automatically on working height
• The sorter selects quality (A/B/C) and type
• Open-block pallets can be nested directly during sorting
• No heavy lifting, no physical stacking
• A quiet, structured workspace away from forklift traffic

With one person making all sorting decisions, the risk of classification errors is minimized and throughput remains stable throughout the shift.

Advantages for the forklift driver

The new setup significantly improves safety and efficiency for the forklift driver:

• Only full stacks are transported → fewer forklift movements
• No interaction with personnel in the sorting area
• Faster cycle times and fewer waiting moments
• Stable flow thanks to continuous infeed and automated stacking

The result is a safer layout with 50% fewer forklift movements compared to manual sorting environments.

Summary

With the installation of the new pallet sorting line, The Pallet Company now benefits from:

• High-speed sorting with twelve stackers
• Processing of Euro, Block (light/medium/heavy) and GMA 48×40 pallets
• Nesting capability for open-block pallets
• A two-person operational setup (1 sorter + 1 forklift driver)
• Higher throughput, lower labour costs and improved workplace safety
• Data-driven reporting through PSS SCADA and CSV files

Pallet Sorting Systems – Modular. Reliable. Efficient.