Pallet Recycling South Wales (PRSW) links existing repair line to double sorting station

Pallet Recycling South Wales – Double pallet sorting line integrated with repair line from Pallet Sorting Systems

Pallet Recycling South Wales (PRSW), a leading player in the pallet recycling sector in Wales, has invested in a double pallet sorting line from Pallet Sorting Systems (PSS).
The new installation is fully integrated with the company’s existing PSS pallet repair line, including a paint booth and HT printer station.
With this expansion, PRSW increases its capacity for sorting IPP pool pallets while improving workplace safety and process efficiency.

Machine description

The new double sorting line is designed for two operators who can inspect and sort pallets simultaneously.
Approved pallets are automatically stacked outside the building, without internal transport or intermediate storage.
Pallets requiring repair are automatically transferred to the connected repair line, ensuring a seamless material flow between sorting and repairing.

After repair, pallets pass through the paint booth where they receive a protective coating, followed by the HT printer station that applies the official HT stamp.
The repaired and certified pallets are then automatically conveyed outside – ready for reuse in the IPP pool system.

This integrated setup minimises manual handling, improves efficiency and ensures a safe, ergonomic and organised working environment.

Benefits for operators

The system was designed with a strong focus on ergonomics and safety:

• No lifting required: sorters and repairers no longer have to manually move pallets – all material handling is automated.

• Fixed workstations: each operator works in a stable position with clear visibility and no unnecessary movement.

• Safe workspace: no forklifts drive around the sorting or repair area, reducing accident risks and creating a calm working environment.

• Efficient cooperation: sorters and repairers work together in a continuous automated flow.

• Ergonomic design: all working heights are adjusted for comfortable and safe operation.

Benefits for the company

For Pallet Recycling South Wales, this investment provides measurable process improvements:

• Higher throughput with two simultaneous sorting operators.

• Reduced cost per pallet through minimal manual handling.

• Full integration with the existing PSS repair line, paint booth and HT printer station.

• Improved safety with separated forklift routes and operator zones.

• Sustainable, circular pallet management within the IPP system.

• Real-time monitoring via PSS SCADA and the PSS Live App.

• Modular system, allowing future expansion or AI integration.

Efficiency and monitoring

The complete line is monitored via the PSS SCADA platform, offering real-time data on:

• total pallets processed,

• performance per operator,

• cycle times and system efficiency.

The PSS Live App provides remote access to production data, enabling managers to monitor performance and optimise processes at any time.

Sustainable and safe solution

With this new double sorting line, Pallet Recycling South Wales strengthens its position as a frontrunner in sustainable and safe pallet recycling.
By combining sorting, repairing, painting and stamping into one automated process, PRSW reduces its environmental footprint while increasing productivity.

Pallet Sorting Systems supports PRSW with decades of expertise in pallet automation, recycling technology, and customised system integration.

Results

With this installation, Pallet Recycling South Wales achieves:

• Higher sorting and repair capacity.

• No lifting for operators – all pallet handling is automated.

• Increased safety through fixed workstations without forklift traffic.

• Fully automated process from sorting to painting and stamping.

• Sustainable reuse of IPP pallets in a circular system.

This project demonstrates how automation, safety and ergonomics can go hand in hand in modern pallet recycling.

Pallet Sorting Systems – Modular. Reliable. Efficient.