Pallet multisort system
MultiSorter – Modular Robotic Pallet Sorting Line | Pallet Sorting Systems (PSS)
What is the MultiSorter?
The robotic pallet sorting system from Pallet Sorting Systems (PSS), known as the MultiSorter, is a modular robotic line that automatically sorts and stacks pallets of all types and dimensions.
This robotic pallet sorting system processes mixed (random) pallet flows, detects pallet dimensions and build automatically, and stacks them interlocked for efficient transport and storage.
The system is suitable for Euro pallets, GMA pallets, Block pallets, and CP pallets (CP3–CP9).
The configuration can be fully adapted to the available space.
A standard setup includes two robots with ten stacking positions each, expandable up to forty positions for larger installations or a broader range of pallet types.
With Ai4Pallets integration, the robotic pallet sorting system automatically recognizes and classifies the wide variety of sorted and repaired pallets.
The operator simply evaluates each pallet based on two criteria: usable or to be repaired.
Pallets requiring repair are routed through the repair workstations and re-introduced into the line, while good pallets are stacked directly by the MultiSorter.
This setup eliminates manual sorting — the MultiSorter and Ai4Pallets handle the process automatically, ensuring consistent quality and reduced physical workload for operators.
Why use a robotic pallet sorting system?
A robotic pallet sorting system offers clear advantages for companies that process large numbers of pallets on a daily basis.
By combining automation with flexibility and data monitoring, the MultiSorter increases both productivity and workplace safety.
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Efficient operation: one robot can process approximately 150 pallets per hour.
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Lower costs: fewer forklift movements and less manual handling.
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Consistent quality: each pallet is placed accurately in the correct stack position.
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Improved ergonomics and safety: operators work outside the robot area and no longer lift heavy pallets.
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Scalable automation: the system grows with operational requirements and can be expanded easily.
Together with Ai4Pallets, this robotic pallet sorting system transforms pallet handling into a streamlined, data-driven process — where the machines handle the sorting and the operator simply manages quality and repair decisions.
Benefits for your organization
Investing in a robotic pallet sorting system provides measurable advantages across several aspects of pallet handling.
From higher capacity and lower operating costs to improved workplace safety — the MultiSorter offers a balanced combination of efficiency and flexibility for both sorting and repair lines.
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High capacity: up to 300 pallets per hour in a dual-robot configuration.
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Modular design: each part of the MultiSorter can be configured or expanded as pallet flows, layouts, or customer needs change.
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Reduced operational costs: fewer forklift movements and less manual work lead to lower labor and energy expenses.
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Flexibility in pallet types: the system processes mixed pallet streams — including Euro, GMA, Block, and CP pallets — without pre-sorting.
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Continuous improvement through data: integrated PSS SCADA and the PSS App provide real-time performance insights, enabling management and maintenance teams to optimize efficiency.
By automating repetitive pallet handling tasks, the MultiSorter helps companies maintain consistent quality, reduce operator strain, and achieve predictable output — even when pallet types and volumes vary day by day.
Efficiency and monitoring – SCADA and the PSS App
The MultiSorter is equipped with PSS SCADA and the PSS App to provide real-time insight into performance, production status, and system efficiency.
These tools give both operators and management a clear overview of the production process — from overall throughput to the performance of each robot.
Through the SCADA dashboard, cycle times, pallet counts, and stack positions are continuously recorded.
The data is automatically stored and can be exported in CSV format for further analysis or integration with existing ERP systems.
The PSS App makes this information accessible anywhere via the internet, allowing managers to track output, uptime, and efficiency remotely.
With real-time data, maintenance and planning teams can react quickly to deviations, reducing downtime and keeping the line running at optimal performance.
Examples of available data:
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Number of pallets processed per hour and per shift
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Occupancy rate of each stacking position
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Operating time and performance per robot
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System status, alarms, and downtime overview
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Production and repair data per operator
Together, the SCADA system and the PSS App make the robotic pallet sorting system fully transparent.
Every pallet movement can be tracked, every process step analyzed — creating a strong foundation for continuous improvement and reliable performance.
Measurable results
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Up to 300 pallets per hour with two robots
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50% fewer forklift movements compared to manual sorting
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Real-time insights through SCADA and the PSS App
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Modular expansion without major modifications
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Less manual handling and improved workplace safety
The result is a streamlined, efficient, and data-driven workflow that increases throughput and ensures consistent pallet quality.
Example configurations
| Configuration | Robots | Stacking positions | Capacity (pallets/hour) | Application |
|---|---|---|---|---|
| Compact | 1 | 10–12 | ±150 | Small sorting line |
| Standard | 2 | 20 | ±300 | Medium-sized pallet operation |
| Extended | 3–4 | 30–40 | ±450–600 | Large sorting or repair centers |
Frequently asked questions – Robotic pallet sorting system
Can the MultiSorter handle size variations?
Yes, the system is designed for used pallets and tolerates variations in length and width.
What happens to damaged pallets?
Damaged pallets are automatically routed to the repair section or stacked separately.
Does the MultiSorter support CP pallets?
Yes, all pallet formats between 1000 and 1300 mm can be processed.
How much space is required?
That depends on the number of robots and stacking positions; PSS provides a layout proposal tailored to each installation.
Summary
The MultiSorter combines flexibility, speed, and visibility in one modular robotic pallet sorting system.
With Ai4Pallets, all pallets — including repaired ones — are automatically recognized and classified, while the operator simply decides whether a pallet is usable or requires repair.
The system reduces manual work, minimizes forklift movements, and provides full visibility through SCADA and the PSS App.
Pallet Sorting Systems – Modular. Reliable. Efficient.
The multisort system in practice
The MultiSorter as an extension to your existing PSS sorting or repair line
Our pallet sorting system and the pallet repair system can be seamlessly combined. This means that you can easily add the pallet repair system to your sorting line, even if the sorting line is already in operation. The repair line can be added in any arrangement you want. You can now easily add a MultiSorter at once to maximize unlimited sorting.
At PSS, everything is modular, so it can easily be expanded with the existing machine parts. This is how we anticipate the future of your business by growing with you as needed.
Efficiency begins with Pallet Sorting Systems
Contact us for personal advice or more information: +31 (0)513 74 52 42
