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Robotic pallet sorting

From mixed pallets to clearly sorted stacks.

Concept solution

Results you can see at a glance

The robot does the handling. Machine vision decides where each pallet goes.

Mixed input becomes sorted output. We inspect pallet colour and type, visible damage and agreed quality criteria. The specific classes and criteria are agreed together with you.

Concept visualisation of robotic pallet sorting with machine vision — Concept visualisation

Layout principle

Two infeeds. Continuous supply.

Separate infeed zones and seven output lanes.

7 outputs – a full stack is collected by forklift.
2 zones – independent safety control of the infeeds.

Schematic layout, not to scale. Robot reach, guarding, clearances and orientation will be verified in the project.

Machine vision

Every pallet passes a visual inspection

Top surface, underside and sides, depending on camera access.

Capture

2D / 3D cameras and suitable lighting.

Evaluation

Algorithms and, where needed, deep learning.

Decision

Assignment of the pallet to an output stack.

We inspect visible defects. The detection scope and processing time will be confirmed by sample tests.

Capacity

4,320 pallets per day

Calculated scenario for 24-hour operation at 75 % utilisation.

For a target of 4,000 pallets per day, 16 h 40 min of net cycle time is enough. The modelled daily reserve is +320 pallets.

Utilisation includes waiting and downtime. The cycle including robot return must be confirmed by simulation.

15sTARGET FULL CYCLE

240PALLETS PER HOUR, THEORETICAL

75%MODELLED UTILISATION

Scope of supply

Complete technology in your plant

Local image processing. One-off runtime licence. No mandatory cloud.

Mechanics

Robot and gripper
Conveyors and centring
Safety components

Controls

Control panel and PLC
Machine vision computer
Cameras and lighting

Commissioning

Installation and integration
Setting the criteria
Testing and handover

System parameters, buffer capacities and scope of supply are defined in the individual project.

Economics

Payback in about one year

Expected scenario: 9 positions freed up in three-shift operation. The economics are based on labour costs; we will use your actual costs.

PRAGMATIC · 6 POSITIONS

18.2 months

€142,000 per year after deducting €8,000 / year

EXPECTED · 9 POSITIONS

11.9 months

€217,000 per year after deducting €8,000 / year

EXTENDED · 12 POSITIONS

8.8 months

€292,000 per year after deducting €8,000 / year

Indicative model, not a quotation. Investment of €160–270k depending on the plant (€215,000 midpoint used in the calculations), modelled operating and service budget of €8,000 / year, modelled annual cost per position of €25,000. Simple payback based on actual cost reduction, excluding financing and ramp-up period.

Alternative for lower volumes

Option to start with a hybrid solution

The robot handles. A person assesses the pallet and selects the target group.

The performance and economics of the hybrid are calculated separately. An operator and safe separation are still required.

Today

Compact cell
Operator decision
Lower initial investment

Later

Adding machine vision
Adjustment to the unstacking
Higher degree of automation

Choosing the robot

Lower CAPEX through the right choice of robot

A new or inspected used industrial robot, depending on the project. Condition matters, not just age.

Payload and reach for the specific gripper.
History, operating hours and technical inspection.
Availability of service, spare parts and safety functions.

Recommended target concept: robot + machine vision.

Next step

We will design a line for your conditions

Your pallets. Your space. Your payback.

A joint site visit is the basis for an accurate technical and economic proposal.

We verify the layout, logistics and sorting criteria.
We calculate the costs of agency and permanent staff, including related expenses.

We will be happy to prepare an individual technical and economic assessment. Output: a tailored solution, budget and return-on-investment calculation.

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