Junction 4 Pallets optimizes pallet management with combined sorting and repair line from Pallet Sorting Systems
Junction 4 Pallets, a prominent player in the pallet industry, has implemented a combined pallet sorting and repair line from Pallet Sorting Systems (PSS). This new line offers efficient solutions for sorting and repairing pallets while significantly improving workflows. With a processing capacity of up to 550 pallets per hour, operated by just one sorter and one forklift driver, the line enhances productivity, reduces forklift movements by 50%, and increases repair efficiency by approximately 35%.
Smart use of stackers: efficiency in sorting and repairing
The combined line is equipped with 12 stackers in total, with 4 located in the repair section and 8 positioned after the repair process. The sorter has access to all 12 stackers, while the pallet repair staff work exclusively with the 8 stackers after the repair section. This setup enables smooth handling of repaired pallets and ensures an efficient sorting process.
These stackers allow pallets to be directly sorted based on type, size, or condition. This reduces manual handling and increases the accuracy and speed of both the repair and sorting processes.
Optimized workflow with upper and lower conveyors
The line features an upper and lower conveyor system to optimize pallet flow. Pallets requiring repair are directed via the upper conveyor to one of the repair stations. Once repaired, the pallets are transported via the lower conveyor to the stackers, where they are sorted and stacked according to specifications. The forklift driver collects the stacked pallets at the desired height, streamlining the process further.
Repair stations: ergonomics and productivity
The repair section includes multiple workstations where damaged pallets are restored. Pallets are automatically delivered to the repair stations at an ergonomic working height, significantly reducing physical strain for the repair staff. This improves working conditions and helps prevent work-related injuries.
The 8 stackers positioned after the repair section enable repaired pallets to be automatically stacked without requiring additional manual intervention. This allows repair staff to focus entirely on their core tasks, resulting in a productivity increase of over 30%.
Real-time insights with SCADA and the PSS App
The line is equipped with PSS’s SCADA system, offering comprehensive monitoring and reporting capabilities. The system tracks data such as the number of repaired pallets, individual staff performance, and overall throughput. These insights are stored in CSV files, which can be easily exported for analysis and reporting purposes.
The PSS App provides managers and operators with live access to operational data via smartphones or tablets. This enables real-time monitoring of the line’s performance, quick identification of bottlenecks, and immediate actions to improve efficiency.
Key benefits of the sorting and repair line
- High capacity: Processes up to 550 pallets per hour with only one sorter and one forklift driver.
- Efficient stacking: 12 stackers in total, with 8 dedicated to repaired pallets.
- Ergonomics: Automatic delivery at an ergonomic height reduces physical strain for repair staff.
- Flexibility: Handles various pallet types without requiring adjustments.
- Real-time monitoring: SCADA and the PSS App provide insights and export options in CSV format.
- Reduced forklift movements: 50% reduction, improving safety and efficiency.
Sustainable and future-focused pallet management
By integrating sorting and repair into a single process, Junction 4 Pallets contributes to more sustainable pallet usage. Extending the lifespan of repaired pallets reduces the demand for new raw materials and lowers operational costs. At the same time, the automated approach improves efficiency and allows the company to quickly adapt to changing customer needs.
The combined sorting and repair line from PSS supports Junction 4 Pallets in their efforts to improve processes, enhance quality, and operate more sustainably. With this technology, the company strengthens its position in the pallet industry and ensures it can meet the demands of a dynamic market.
