Sorting used pallets with Pallet Sorting Systems

Manual sorting, stacking and grading are no longer necessary. With the Pallet Sorting System from Pallet Sorting Systems (PSS) you automate the process at the touch of a button and raise efficiency across your operation. With one sorting operator and one forklift driver, it is possible to sort or de-stack up to 600 pallets per hour. The current hour record is held by LECARO with 612 pallets/hour de-stacking.

Ergonomic, safe workflow

Our sorting lines handle Europallets, Block pallets (light, medium, heavy) and GMA pallets without changeovers. Operators no longer lift heavy loads or work close to moving forklifts; the line takes over feeding, sorting and stacking. The result is a safer work environment and a steady, predictable flow.

Efficient sorting of used pallets

Used pallets arrive in mixed types and grades. PSS lines sort by type, quality and defects to create clean, sale-ready stacks.

Smart options

• Sorting assistant for guided decisions

• Ai4Pallets to automatically categorise and group pallets for faster, more consistent results and lower handling costs

Throughput & staffing

• Baseline: 1 sorting operator + 1 forklift driver

• Modes: sorting to multiple stacks or high-speed de-stacking

• Rate: up to 600 pph with constant infeed; site results depend on supply, removal and housekeeping

Formats handled

• Europallets

• Block pallets (light/medium/heavy)

• GMA pallets

Looking to streamline used-pallet operations? PSS designs modular systems that fit your layout and volumes, from simple de-stacking to multi-grade sorting with Ai4Pallets.

Why pallet reuse is and will become so important

Pallet reuse plays a crucial role in the circular economy, in which raw materials are optimally utilized and waste is reduced. New EU legislation, such as European Directive 94/62/EC on packaging and packaging waste, requires companies to reduce their environmental impact by responsibly managing packaging materials, including pallets.

This directive requires companies to promote reuse and recycling of pallets to make pallets last longer and achieve environmental goals. With our Pallet Sorting Repair Lines, companies can reuse pallets efficiently and comply with laws and regulations.

New in 2025 is the PSS Robotic Pallet Dismanter, Following the guidelines, PSS is moving forward with developments and the first step is that pallets that cannot be repaired because it is no longer economically viable to do so will be stripped fully automatically and the boards and chocks that are then released will be reused to repair the pallets that can be repaired.

Ergonomics, efficiency and safety all in one.

Automatic pallet sorting also offers significant benefits in terms of ergonomics, efficiency and safety.

• Sorters no longer have to work in close proximity to forklifts, reducing the risk of accidents.
• In addition, the automated system reduces forklift movements by 50%, creating a safer and clearer working environment.
• The machine takes over the heavy lifting and sorting work, significantly reducing the physical strain on employees and improving working conditions.
• PSS is represented with pallet sorting machines in 20 countries with their specific safety requirements. We have made it our standard to take all measures into account in design and application.

NEN standard for lifting and carrying

The international standard for lifting and carrying – NEN-ISO 11228-1:2003 – has been revised. Experts from 15 different countries worked on the revision. The revision was carried out under the leadership of a Dutch chairman and under the secretariat of NEN. The standard contains limit values for lifting related to the number of lifting operations and the lifting distance. It is a very specific standard that is directly applicable in practice.

The European standard for lifting is 18 kg at a continuous load, this includes requirements for conditions.

Configuration tailored to your needs

The configuration of the Pallet Sorting Line is fully customized to your needs and requirements. This means you can choose the modules that best suit your business and the types of pallets you handle. Whether you are sorting europallets, block pallets or pallets of all sizes – the pallet sorting system can be configured according to your work process

Fixed and adjustable variants

The pallet sorting system is available in several versions, and these can also be combined:

• The Standard Pallet Sorting Line is suitable for the most common pallets, such as euro and block pallets in light, medium and heavy duty and 48×40 inch GMA pallets, without adjustment .
• The Adjustable pallet sorting line: In addition to the above pallets, the adjustable sorting line is also automatically adjustable for other pallet sizes such as CP3, CP4, CP5, CP7, CP8 and CP9 pallets., because all stackers adjust to the desired size at the push of a button, presorting is a must here. This means that you can sort all pallets in 1x with a length dimension of about 1200 long such as euro and block pallets in light, medium and heavy duty as well as 48×40 inch GMA pallets, without repositioning. Then if you want to sort the CP3,CP4,CP8and CP9 or other pallets with a length dimension between 1100 and 1150 you can also do that without repositioning.
• The Multisorter can handle all pallets with a length between 1000 MM and 1300 MM without any changeover .

Practical office functions and real-time data analysis

In addition, we offer practical functions such as PSS Scada, a direct interface for the office with CSV files for your administration with data acquisition. This allows you to analyze sorting data in real time and monitor the performance of your sorting system. With the pallet sorting system, you have an efficient and flexible pallet sorting solution that saves costs and increases productivity.

Efficiency starts with pallet sorting systems

Visit our project page to see several installed machines, or contact us directly for personal advice or more information: +31 (0)513 74 52 42.