Pallet Sorting Systems (PSS) is supplying a combined pallet sorting and repair line to Pallet Match in Ireland. The installation features six automatic pallet stackers and two integrated pallet repair stations. With this investment, Pallet Match is choosing an efficient, ergonomic and future-proof solution for sorting and repairing used pallets.

By combining sorting and repair operations into one integrated system, manual pallet handling is significantly reduced, creating a more efficient and continuous pallet flow throughout the facility.

Efficient Pallet Sorting with Minimal Labour Requirements

The new pallet sorting line enables Pallet Match to achieve high sorting capacity with just one sorting operator and one forklift driver.

The system is designed to process up to 550 pallets per hour, depending on the pallet mix and the condition of the incoming pallets.

During the sorting process, the operator inspects each pallet for its type, quality and possible damage. The system then automatically transports the pallet to the appropriate stacking position or repair section.

The main advantages include:

• Up to 550 pallets per hour with one sorting operator and one forklift driver.
• Labour savings equivalent to 2–3 sorting operators compared to traditional manual sorting.
• More than 50% fewer forklift movements around the sorting process.
• Six automatic pallet stackers for separating different pallet types and quality grades.
• Consistent sorting quality and a well-organised, ergonomic working environment.

Two Integrated Pallet Repair Stations

One of the key advantages of this combined installation is the direct connection between the sorting process and pallet repair operations.

During inspection, pallets requiring repair are automatically separated from pallets that can be reused immediately. Damaged pallets are then transported to the two integrated repair stations.

This ensures that repair operators receive only pallets that actually require repair. Unnecessary manual pre-sorting and pallet movements are eliminated.

As a result, repair efficiency increases, allowing operators to spend more time on actual repair work rather than handling and sorting pallets.

The combination of automated sorting and integrated repair stations creates a continuous pallet flow and increases overall processing efficiency.

SCADA Technology and Real-Time Production Monitoring

The pallet sorting line is equipped with the PSS SCADA control system, which automatically collects important production data, including:

• Number of pallets sorted.
• Number of pallets repaired.
• Operating hours and production performance.
• Distribution of pallets across different sorting positions.

Through the PSS App, Pallet Match can monitor the current status and performance of the installation in real time.

In addition, daily production reports are available in CSV format. These reports provide valuable insights into productivity and support further analysis and optimisation of operational processes.

Modular Design for Future Expansion

Like all Pallet Sorting Systems installations, this combined pallet sorting and repair line is built using standardised modular components.

This modular design allows the system to be expanded or adapted as production requirements change.

Possible future extensions include:

• Additional pallet repair stations to increase repair capacity.
• Paintbooth for automatically painting pool pallets.
• Nail Press for pressing protruding nails back into the pallet deck.
• Additional sorting capacity by increasing the number of stacking positions.

Thanks to its modular construction, the installation can grow alongside Pallet Match’s future operational needs.

An Efficient and Future-Proof Investment

With its new combined pallet sorting and repair line, Pallet Match is investing in a solution focused on labour savings, high capacity and reliable quality control.

The combination of six automatic stackers, two integrated repair stations and real-time production monitoring provides a solid foundation for continued growth and operational optimisation.

Pallet Sorting Systems appreciates the trust placed in PSS by Pallet Match and looks forward to a successful partnership.

Pallet Sorting Systems – Modular. Reliable. Efficient.