Dismantling used and scrap pallets to recover usable lumber is a key task for pallet recycling operations.
Dismantling pallets provides a steady stream of raw material for repair stock to refurbish pallets, for assembling ‘combo’ pallets made of new and used lumber, and building pallets of 100 percent recycled material.
There are essentially two types of pallet dismantlers that machinery suppliers have developed over the years: bandsaw dismantlers and rotary or shear dismantlers.
Bandsaw dismantlers feature a fast-moving bandsaw blade, and the pallet is pulled toward the worker, into the blade, separating deck boards from stringers. The pallet is manually turned over to complete the process. The machines can be configured for one-man or two-man operation.
Rotary or shear dismantlers feature a set of circular steel plates that separate the deck boards and stringers as the pallet is mechanically pushed through the ‘heads’ of steel plates. Like the bandsaw machine, the pallet is flipped over manually to complete the process. Rotary machines require only one operator.
Rotary or shear machines require less work since the machine is pushing the pallet through the head — unlike a bandsaw machine, which requires the worker to pull the pallet through the saw.
Of course, there are other factors to consider in deciding on a machine for pallet dismantling, including cost, the number of operators, projected production, maintenance ease, blade replacement, etc.
Manufacturers and suppliers offer various options and models for recyclers. These include machines with a table or surface that can accommodate pallets of various sizes, power options, different systems (tires or steel wheels) for running band blades, and more. Some models feature a trough or other feature that allows the reclaimed material to slide or drop off the machine to an area to be accumulated; conveyors can be configured with these features so that lumber is automatically carried away. The dismantler can be configured in-line with a conveyor bringing the material directly to a trim saw for lumber to be cut to length. Conveyors also can be added to bring pallets to the dismantler. Some manufactures even provide portable, towable models that can be easily transported to a customer location to perform dismantling on-site.
These options can automate tasks and reduce labor, reducing steps that otherwise would be taken by workers to handle and move reclaimed lumber. These options can improve efficiency production as well as reducing the labor and fatigue of workers.
Following is information about manufacturers and suppliers of pallet dismantlers. Some companies specialize in one type, some offer both.
Bronco Pallet Systems
Morris Self
(800) 458-5462
Bronco Pallet Systems offers a leverage dismantler for disassembling pallets. It is an air-powered machine that pulls the deck board away from the stringers without damaging the stringers. The dismantler removes the board and also some of the nails.
One operator can dismantle 60-80 pallets per hour, 400-600 per day, depending on the quality of the pallets.
The machine features a safety bar across the back that prevents pallet parts from being discharged toward the operator.
The Bronco leverage dismantler can be used to disassemble both stringer and block pallets, and it is adjustable for different size pallets.
Unlike a bandsaw pallet dismantler, no blades are required. With no hydraulic or electric components, the machine is low on maintenance. Bronco has a five-year warranty on parts.
The machine operates on 100 PSI compressed air. It also features air couplers for pneumatic nailers and hand-held platers and can function as a pallet repair work station.
PRS Group
Jeff Williams
(217) 291-0009
PRS offers a multitude of pallet dismantling solutions to accommodate any pallet recycler’s needs. The variety of machines includes several bandsaw models: SPARTAN Bandsaw, PROSAW Band Dismantlers (models 15, AT, and AT-15), PROSAW Band Dismantler XP, PROSAW XP-ONE, and PROSAW XP-TWO. PRS also offers two rotary type dismantlers: Recycler Single and Recycler 3-Head Pallet Dismantlers.
The most economical model is the SPARTAN Bandsaw, which can be operated by one or two people. It cuts smoothly with a 10 hp direct drive saw motor that sets the blade speed at 2,200 surface feet per minute. The machine features a 21-foot, 9-inch blade, a heavy-duty gear reducer, and simple mechanical blade tensioning. The SPARTAN line also includes an adjustable table model.
PROSAW Band Dismantlers have become known as the heavyweight production machine of choice. These dismantlers are high-speed, belt-driven, and are available in both 10 hp and 15 hp models. PRS offers models with fixed table heights, electronically adjustable table heights, one or two operator designs, and lumber chutes.
For high-volume pallet dismantling requirements, consider the PROSAW XP-TWO dismantling system. It includes two bandsaws and two lumber conveyors. This system includes two 15 hp PROSAW Dismantlers with integral lumber chutes. The 20×1 troughed belt conveyor and 10×1 troughed belt conveyor provide efficient material handling and higher production rates. Each XP-TWO requires only one operator, reducing labor.
PRS invented and patented 3-head rotary pallet dismantling equipment several decades ago. It continues to manufacture an industry-leading, heavy-duty version – the Recycler 3-Head. This machine makes it easy to dismantle 3-stringer pallets. Powerful 15 hp hydraulics drive the pusher ram to do all the hard work. Blades made of tool steel shear the nails and hold up to years of continuous service. Lumber conveyors are built into the Recycler 3-Head to complement the machine’s high production capacity.
Saw Service & Supply
Gary Snyder
(800) 735-5604
garysnyder@sawserviceandsupply.com
The Hawk bandsaw pallet dismantler offered by Saw Service & Supply was designed with two objectives: increase production, and increase blade life.
The Hawk is a high-speed pallet dismantler featuring a blade speed of 3,900 surface feet per minute. Although it is designed as a two-man machine, it has a removable flip bar and can be operated by one man.
The Hawk has the capability to dismantle 60 to 90 pallets per hour. Although your results may vary, that equates to an average of over 600 pallets per day.
The machine has a feed-side pivot plate that enables the operator to find the slot between the deck board and stringer. This feature eliminates the need for an adjustable table and additional motor.
The Hawk drive train consists of the largest tires in the industry. It features 31-inch diameter truck tires and rims — the largest diameter tires for any dismantler. This feature extends blade life significantly by reducing blade stress and fatigue. Saw Service says you will dismantle more pallets per blade with the Hawk! The pneumatic air bag for tensioning the blade is another feature that adds to blade life.
The Hawk is built ruggedly. It is fabricated with 4×4 square steel, and the deck is manufactured with 5/8-inch steel. It is powered by a three-phase electric 15 hp motor, standard, for lots of power.
For more information about the Hawk and what it can for you, contact Gary Snyder at Saw Service & Supply at the number listed above.
Smart Products
Ken Hess
(765) 284-9545
Smart Products offers several bandsaw machines: one-operator machines, two-operator machines, systems complete with conveyor and trim saw, and portable machines.
The Smart Products one-man bandsaw dismantler can disassemble 600 pallets per 8-hour shift. Blade life, in most cases, ranges from 1,000 to 1,500 pallets. The base machines have either a 52-inch or 64-inch capacity and are powered by a 10 HP Baldor motor with a choice of gear reduction units that will drive the blade at 2,600 feet per minute or 3,700 feet per minute. Other features include improved hydraulic blade tensioning, durable blade guide bearings for low maintenance, and push-button table height adjustment. Options include: deck board conveyors for disassembled lumber transport, single-phase electric motors, gasoline powered engines (Honda 20.2 HP units are standard), and “quick-adjust” tables to accommodate the prep for repair, or complete disassembly of various styles and types of pallets.
The company’s two-man bandsaw dismantler can be used to disassemble pallets as well. Base machines also start at capacity of 52 inches or 64 inches and are powered similarly as the 1-person machines with options and features that mirror its 1-person styles as well.
The base Smart Products pallet dismantler system (PDS), consists of a 1- person front discharge style dismantler dropping boards onto a 17’ long accumulating chain conveyor (ACC). At the end of the ACC is a connected single-end power feed trim saw (can be either inclined or flat) loaded by 1 operator. The Smart Products PDS can achieve production levels of over 1,000 pallets per 8-hour shift. Optional chutes attached to the ACC allow for the placement of an additional dismantler to the side of the ACC that will allow operators to double the production levels that can be achieved from this PDS. Optional scrap conveyors allow for “hands-free” collection of scrap from the trim saw to go directly into a dumpster for disposition.
The Smart Products portable dismantler is a towable unit powered by a Honda 20.2 HP gasoline engine with electric start. Available in either 52-inch or 64-inch capacity, this normally 2-person machine can dismantle up to 700 pallets per 8-hour shift. It has many of the same features, including push-button table height adjustment, improved hydraulic blade tensioning, and durable blade guide bearings for low maintenance.
SMETCO
Ken Butler
(800) 253-5400
SMETCO introduced its first bandsaw dismantler in 1996, and it has made significant improvements over the years.
The SMETCO bandsaw dismantling machine is extremely versatile. It can be used for both one-man and two-man pallet dismantling operations.
One of the features that sets SMETCO machines apart is the 24-inch steel band wheels instead of tires. Steel wheels maintain an even curve pattern on the blade, which contributes to longer blade life. The wheels are machined, crowned, and balanced for superior blade tracking and smooth operation.
SMETCO’s patented ‘curved’ fence contributes to the ease and safety of rocking the pallet back and forth as you run the pallet through the blade. Manual table height adjustment is standard, but an electric table actuator is an option.
The blade is tensioned with an airbag that maintains even pressure. The blade tensioning system features heat-treated V-guide bearing guides and phenolic blocks to keep the blade in place.
The standard machine is powered with a 15 hp TEFC electric motor. SMETCO manufactures the main bearings. Tapered roller bearing design and an oil bath keep the bearings cool.
Options include: 3-phase or single-phase electric power, gas engine, resaw package, electric table adjustment actuator, and take-away belt conveyors. Larger top guarding and lock-out electrical switches on cabinet doors are offered for added safety.
For more information, contact SMETCO.
Universal Machinery Sales
Mona C. Tracy
(812) 298-8090
sales.universalmachinerysales@gmail.com
www.universalmachinerysales.net
Universal Machinery Sales offers several equipment solutions for pallet disassembly, including both bandsaw and disc-type machines.
The Run-A-Gade and Mark-I bandsaw disassemblers are machines your company can grow with.
The basic Mark I can be an independent machine to disassemble pallets. Add a conveyor system later, and two of the machines can be operated in tandem.
One man operating the Mark I can disassemble 400-700 pallets per 8-hour shift. It also can be set up for two-man operation.
The Mark I has a large 62-inch table standard along with adjustable stringer height. It is powered by a 10 hp single or three-phase electric motor.
The Run-A-Gade, designed with the machine and a conveyor system, is the top of the line disassembler featuring solid construction, excellent safety and handling. It is equipped with a 15 hp motor for faster speed, allowing greater yield in processing used pallets to reclaim and recycle lumber. The Run-A-Gade features longer blade life along with pneumatic blade tensioning and heavy-duty guides. Designed for one-man operation, a two-man configuration is available.
Both the Mark I and the Run-A-Gade are designed to maximize blade life. The ease of movement and rapid pallet disassembly will help grow your profits. Universal Machinery will gladly refer you to customers who own and operate these machines so you can learn first-hand how well the machines have produced for them.
The Trio is a shear or disc style pallet disassembler for high production. It can disassemble 800-1,000 pallets in an 8-hour shift.
This 3-head machine is equipped with a 15 hp motor and features a safe hand lever operation. The Trio offers long blade life and a low scrap ratio. It can disassemble pallets up to 54×62.
With takeaway conveyors and separation of materials, the Trio reduces labor for your operator.
Universal also offers the Solo single-head disc-type machine to disassemble a single stringer of an entire pallet.
For more information about any of these machines, contact Mona C. Tracy at Universal Machinery Sales at the number listed above.
Wood-Mizer
Brad Kirkaldy
(765) 228-6775
The Wood-Mizer Pallet Hawg® PD200 Bandsaw Pallet Dismantler is engineered for a full range of pallet recycling tasks, including pallet prep, repair, dismantling, and lumber recovery.
Designed for one or two operators, it is available in 60-inch, 72-inch, 84-inch, or 96-inch wide table capacities. The PD200 also is available with many customizable options to fit the needs of your operations, including 10 hp electric or 19 hp gas power, trailer package, rear or center drop table, and front or rear board catch.
Average production will vary per 8-hour shift, but the PD200 is designed to dismantle approximately 400 pallets per shift with one operator.
Two easily removable pass back bars located above the blade allow for a quick transition between a two-person and one-person operation.
A pneumatic table lift has preset heights with 5-½ inches of travel below the blade to enable quick, convenient shifting between upper and lower cut points to easily adjust for block pallets, stringer pallets, or specialty pallets and skids.
The bi-metal bandsaw blade runs at 2,200 feet per minute. Due to the unique combination of high torque and low RPMs, the blade has an expected life of up to 1,500 dismantled pallets, which is nearly double the blade life of other pallet dismantling saws.
A mechanical blade tensioning system ensures proper blade tension at all times, unlike air or hydraulic blade tensioning systems. Removable cabinets allow for easy access to the two 27-inch bias ply tires and blade guide assemblies for maintenance.
Two operator remote stop buttons are available near the table height adjustment for safety, and two built-in forklift pockets allow for easy loading and unloading of the machine for layout flexibility.
Built in the U.S. from premium quality components, the Wood-Mizer PD200 Bandsaw Pallet Dismantler is designed for low maintenance costs and years of trouble-free service.
Contact Wood-Mizer pallet recycling specialist Brad Kirkaldy for more information.
Heartland Fabrication & Machine
Erick Finke
(800) 422-2215
Heartland Fabrication & Machine has over 25 years of experience building machinery for the pallet and lumber industries. The company utilizes proven designs and solid construction to provide dependable, affordable machinery.
The Heartland B60 bandsaw dismantler is available in four sizes and can be customized with various options. The B60, the standard model, has a 60-inch table and can be operated either by one man or two. One man can dismantle up to 300 pallets per 8-hour shift, and two men, 500.
The standard B60 model uses a 24-foot blade that runs at 4,200 feet per minute. It is powered by a 10 hp motor. It features a pneumatic blade tensioning system and a guide system with dual roller bearings. Table adjustment is pneumatically controlled.
Heartland offers numerous options, including larger table, 15 hp motor, conveyors, and more. The company also offers systems featuring multiple machines operating in-line with conveyors to collect the reclaimed lumber.
For more information, call Erick Finke at Heartland Fabrication & Machine at the number listed above.
Industrial Resources
Gerry Dykstra
(616) 791-7500
Industrial Resources offers two models of bandsaw dismantlers for lumber recovery and recycling operations.
The Wolverine II offers industry-leading components as standard equipment, including a pneumatic, automatic-constant pressure blade tensioning system for longer blade life and a quick blade change system to reduce downtime. The Wolverine II operates with a 23-foot, 9-inch blade and can dismantle 400-600 pallets per shift with one worker. Features include 64-inch wide table, push-button table adjustment, large diameter pneumatic drive and idler tires, and high-speed, high-torque 15 hp motor. It can be combined with conveyors and an Industrial Resources trim saw for a complete wood recovery system. Options include two-man configuration, single-phase power and variable speed motor.
The Rapid Cut II, for high-volume production, quickly removes top or bottom boards from any stringer pallet in seconds. One operator can disassemble 800-1,000 pallets per shift.
The Rapid Cut II, which also has a 64-inch wide table, runs a 22-foot, 10-inch blade and features an extreme heavy-duty blade guide system and a high-torque drive train. The 15 hp direct drive motor powers the blade to 4,200 feet per minute. Other features include adjustable table height and air spring tensioning for reduced blade shock.
For more information, call Martin VanDenack.
