The world of pallet cut stock production is changing, and Max Board Feet (MAX), a division of Automated Industrial Technologies (AIT), is charting the future today.
With a focus on fully integrated automation, custom engineering, problem-solving expertise and customer service excellence, MAX is helping sawmills and pallet manufacturers achieve higher production without increasing labor costs. While integrated automation has long been a staple in industries like automotive and aerospace, other industries that AIT serves, the pallet industry has lagged—until now.
The Power of Integration: Making Machines Talk
Over the decades, cut stock production has evolved from a multiple-production-cell approach—requiring material to be repeatedly stacked and moved by forklift between stations—to in-line solutions. However, even in in-line systems, machine operators are still required to manually communicate and coordinate. This outdated approach often leads to bottlenecks, downtime and inefficiencies. MAX is changing that by designing fully integrated production lines where machines “talk” to each other, creating seamless, consistent material flow.
“If you go back 10 years, a typical line was five standalone machines with conveyors in between them,” explained Chip Lamb, CFO of AIT. “If something jammed at the stacker, Bob would have to wave his arms, Joe would stop the trim saw, and everything would back up. It was chaotic. Now, with our networked systems, if Bob’s stacker slows down, the system automatically adjusts the trim saw and resaw speeds. The whole line stays in sync.”
The key to this advancement is MAX’s use of programmable logic controllers (PLCs) and Ethernet networking. Each major machine in a MAX line has its own PLC that monitors performance and adjusts output as needed. The result? A smoother operation with less downtime and fewer disruptions.
MAX’s integration expertise isn’t limited to its proprietary machinery. The company has successfully networked third-party trim saws, resaws and ripsaws into its lines. One notable case involved integrating a competitor’s trim saw and ripsaw into a MAX system using real-time feedback loops. “We developed a setup where the trim saw adjusted its speed based on the backlog feeding into the ripsaw,” Lamb stated. “That meant the ripsaw could work at maximum efficiency without becoming a bottleneck. That level of optimization wasn’t even on the radar for most pallet manufacturers five years ago.”
Automation That Saves Labor and Reduces Variability
For many manufacturers, the biggest initial driver toward automation is labor savings. MAX’s M2L series board stackers are a prime example. “With an M2L stacker, you go from three employees stacking manually to one person overseeing grading,” commented Lamb. “Not only do you save labor, but you eliminate human variability and inconsistency. The output becomes predictable, manageable and repeatable.”
The experience of a Midwest hardwood pallet producer demonstrates the impact. The company was struggling with labor shortages and inefficiencies, manually sorting, grading and stacking boards. After installing a MAX M2L board stacker and unscrambler, this pallet manufacturer saw immediate results. “The same employee who used to grade, sort, and stack is now just pulling irregular boards and monitoring the system,” the company’s owner explained. “We didn’t add any labor—we just gave that employee a safer, less exhausting job and got more speed on our cut-up line.”
The impact? A 40% increase in production volume per shift, allowing the company to meet customer demand without adding workers.
Beyond stacking, MAX has helped businesses optimize entire operations. In one case, a company was puzzled by a saw’s underperformance. The issue wasn’t mechanical—it was logistical. Busy forklift drivers struggled to keep up with feeding material to the saw, leading to as much as a 15-minute delay between packs. The solution? MAX recommended adding five feet of load deck space so that the forklift driver could place the additional bundle before the saw operator ran out of material. That simple adjustment increased throughput by 40%.
“Sometimes, automation isn’t about adding machines,” Lamb observed. “It’s about understanding the flow of material and removing inefficiencies. That’s where our expertise makes a real difference.”
Unmatched Customer Service and Custom Engineering
Lamb is excited to talk about MAX’s investment in customer service. Keith Graham, MAX’s customer service manager, plays a key role in ensuring customers get the most out of their systems. “Keith knows these machines inside and out,” said Lamb. “He’s been in the trenches with customers, troubleshooting everything from minor sensor issues to full system overhauls. He understands how every piece of the operation fits together.”
MAX offers on-site and phone support, not just for initial startup, but for ongoing troubleshooting. Customers don’t just buy machines; they gain a partner invested in their success. If a machine is down, MAX’s service team—comprised of field technicians and engineers—works rapidly to diagnose and resolve the issue. Lamb remarked that MAX currently has an installation base of over 750 machines. “We know what lasts, and we continuously evolve our equipment based on what we learn in the field.”
Customization is another key differentiator. Around 50% of MAX’s pallet cut stock line equipment includes some level of modification. Whether it’s altering a stacker to handle a wany or unusually sized board or tackling another unique challenge, MAX thrives on innovation. “We’ve done everything from modifying standard equipment to designing a custom ink-stamping solution for dunnage,” Lamb explained. “If a customer has a particular need, we can almost always engineer a solution.”
MAX’s service team also plays a critical role in guiding customers toward better long-term solutions. From addressing flow issues to resolving maintenance concerns, their hands-on expertise makes a difference. The team understands that even small changes—like sensor adjustments or conveyor placement—can significantly impact performance.
As automation becomes more prevalent in the pallet and sawmill industries, MAX continues to push the boundaries. The company is actively working to improve cross-vendor machine integration, tackling the challenge of varying control systems and communication protocols.
“Most customers want a front-to-back solution from one vendor, but no single company makes the best version of every machine,” Lamb suggested. “That’s why we specialize in making different brands talk to each other. We retrofit control systems and build communication bridges to ensure seamless operation if needed.”
The philosophy behind MAX’s approach is simple – a consistent, steady production line is always better than one that swings between overproduction and downtime. “It’s better to run at 300 feet per minute consistently than 400 feet per minute with constant stops,” Lamb stated. “That’s what integrated automation delivers—reliable, optimized throughput.”
With industry demand rising, labor markets tightening and supply chain disruptions still a reality, companies that embrace integrated automation will have the advantage. MAX stands ready to help businesses navigate this transition with smart engineering, customized solutions and top-notch customer support.
