Pallet Dismantlers Provide for Efficient Tear Down of Broken Pallets, Improve Lumber Recovery

Pallet recyclers are always looking for creative and cost-effective ways to reclaim as much material as possible. One of the most popular machines to improve lumber recovery from used pallets is the pallet dismantler. This machine is used to cut or force apart the nails holding the boards together and to assist in quickly and efficiently disassembling a pallet.

Recycled lumber can be used for repair stock or for assembling combo pallets made of new stringers and used deckboards.

Machinery manufacturers offer a few major types of dismantlers – bandsaws or rotary disc dismantlers. A third type uses leverage to pull deck boards from the stringers. Due to their speed and efficiency, bandsaw dismantlers have become the most common solution, especially in North America.

Bandsaw dismantlers use a disposable, fast-moving, metal-cutting bandsaw blade. The worker pushes or pulls the pallet toward him, into the blade, severing the nails and separating the deck boards from the stringers. The worker turns the pallet over to complete the process. The machines can be configured to be operated by one person or two. One disadvantage of this approach is that it is more physically taxing than other types of equipment because the operator is physically maneuvering the pallet into the blade and also turning the pallet over.

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. This type of machine requires only one operator. The dismantler does all the work of separating the lumber, but like the bandsaw machine, the worker still must turn over the pallet to complete the process.

The third type of dismantling machine uses pneumatic-powered leverage to separate the deck boards from the stringers. Like the rotary or shear type, the machine does the work of separating the lumber, but the worker still must feed the pallet into the equipment and turn it over to complete the process.

Manufacturers and suppliers offer various models and options. 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 bandsaw blades, and more. Some suppliers offer bandsaw machines with adjustable table height and a blade guard.

Some models may feature a trough or other feature that allows the reclaimed material to slide or drop off the machine to an area to be accumulated. They can be configured with conveyors, so the reclaimed lumber is automatically carried away. For example, the dismantler can be configured with a conveyor to carry the lumber directly to a trim saw to be cut to length. Some manufacturers offer portable, towable models that can be easily transported to a customer location to perform dismantling on-site. Other approaches used scissor lifts and round tables to help with the materials handling process.

Conveyors and other equipment can be added to bring pallets to the dismantler, eliminating the labor involved in manually pulling pallets down one at a time from a stack and placing them on the machine. Tippers, de-stackers or dispensers and other equipment can bring the pallet to the workstation at the same level as the machine, eliminating the hard work of lifting and carrying pallets. These options can automate tasks and reduce labor. By eliminating unnecessary steps, these options can improve efficiency and production as well as reduce the labor and fatigue of workers.

Some other things to consider when selecting the right pallet dismantling option. Jeff Williams, president of PRS Group, pointed to the operation flow of your plant. He said, “An important variable is the inbound of pallets to dismantling. Were the pallets pre-sorted to ensure sellable or repairable pallets are not being dismantled? Other unnecessary cost is to re-route and move sellable and repairable pallets from dismantling back to inventory or other process areas. Another consideration is sending smaller pallets to one-operator bandsaw dismantlers and larger/heavier pallets to two-operator bandsaws.”

Others may not even be aware of the benefits of using recycled lumber. Martin VanDenack, president of Industrial Resources, cautioned, “Some people don’t understand when it comes to wood recovery how much wood they go through. And they don’t realize how much money they can save by using recycled wood versus new wood. Once people understand how much money they can save by using recycled wood, many go that route.”

There are different types of solutions that can be deployed. Mona Tracy, president of Universal Machinery Sales, “Pallet disassembly has become a big part of the pallet recycling business. Having the right machine for the pallets you are disassembling is key to good production. We have disc type machines that can tear down stringer pallets, but they don’t do block pallets as well. A bandsaw machine will do both block and stringer pallets, but you have greater blade cost associated with the bandsaw process.”

Removing manual handling is another way to cut operation cost. Brad Kirkaldy, pallet recycling specialist for Wood-Mizer, explained, “Material transfer conveyors can increase production by 50% or more. The rear drop or center drop machines can be combined with belt and chain transfer conveyors to the trim saw. This eliminates handling and sorting material between the dismantlers and trim saw. Less hands on the material equals more production.”

Also, when it comes to operating costs, some things that people forget to factor into their decision process are consumables. Kirkaldy noted, “Consumable costs can get overlooked. This includes blade life, blade cost per pallet, guide bearing cost, etc.” Some popular add-ons for the Pallet Hawg® are rear drop and center drop tables, as well as table extensions for bigger pallet sizes.

Tracy of Universal Machinery suggested, “Take away conveyors, round tables, and stacking racks for sorted material are just a few of the features that can be added for greater production and labor savings.”

VanDenack stated, “The popular features that people are looking for are safety devices to ensure that they comply with OSHA. Unfortunately, there are limitations on how safe these bandsaw dismantler machines can be made while still allowing for efficient production.”

For example, some suppliers offer a bar that acts like a bump stop, and if an operator comes in contact with that bar, the saw stops because the operator may be too close to the saw. VanDenack suggested, “This bump stop shows OSHA that a company is trying to be safe even though you can’t completely eliminate all risks with the traditional design. You usually get more understanding from the inspector if you have this safety bar in place.”

VanDenack said, “We are seeing more and more customers ask for enhanced safety features because they have had concerns raised by OSHA or know that is something that others have faced.” This is especially true in Canada, which has more stringent safety standards than the United States.

The Pallet Enterprise Dismantler Guide features some of the top technology and suppliers offering various pallet disassembly equipment. This guide includes descriptions of various solutions, highlighting advantages and approaches. Suppliers are listed in alphabetical order.

 

Key Questions to Consider When Selecting the Right Pallet Dismantler or Disassembly Solution

 

1.) Your Current Process – You need to look at your current process and figure out where your bottlenecks are. What is working and what is not? What is taking too much time or manpower? If you have existing dismantlers, consider these questions: What do the operators like about them? What features would help them the most? From a business standpoint, what are the negatives about your current process? You may find out that you don’t need a new dismantler. But you need conveyors and handling equipment to enhance your current process.

2.) Production Requirements – How many pallets do you need to process per hour? How many workers are you currently using? To trim staff costs, how would you like to use improved automation to reduce headcount in this department?

3.) Cost – Probably the biggest factor is cost. But that can go way beyond just the purchase price of the machine. You may need to figure out everything from efficiency per operator to bandsaw blade utilization to the purchase price, average maintenance costs, safety-related costs, return on investment, etc. Are you looking at a new or used machine? Sometimes old machines are just buying someone else’s headaches. So be careful to conduct a thorough inspection of any used machine. Not all used pieces of equipment are created equal.

4.) Advanced Automation – Some of the solutions involve advanced automation, such as robotics. While this can improve safety and performance, you do need to have people who can operate and service this higher level of equipment. The good news is that robotics has already come a long way in this industry.

5.) Features – Some dismantlers come with special features, such as adjustable tables or advanced safety guards. Make a list of what you want and see if you can find a good fit.

6.) Experience/Live Demo – What pieces of equipment do you know have worked well for others? Ask around and talk with others in the industry. Maybe go to see machinery run at another live pallet shop. Research equipment success stories at www.palletenterprise.com. Then, call the pallet companies and get their first-hand experience.

7.) Performance – Production isn’t everything if the end product is poor. Look to see the quality of the lumber produced. Can the dismantler handle the common sizes that you encounter?

8.) Maintenance – Is the machine bulletproof? Is it robust or made with cheap parts? Can you find parts easily? Are off-the-shelf parts used? What type of training and manuals are provided by the supplier? Does the dismantler go through blades at a higher than normal rate? Beware that this may result from using the wrong blade or setting on the machines, not the machine itself.

 

Alliance Automation

(419) 238-2520

info@allianceautomation.com

www.allianceautomation.com

 

Alliance Automation has transformed the pallet and lumber industry by combining cutting-edge innovation with a commitment to automation. Its ground-breaking Robotic Pallet Dismantler is a game-changing solution designed to tackle industry safety and labor challenges head-on. This highly versatile system delivers consistent throughput and increased output while significantly reducing the need for physical labor. Capable of handling a wide variety of pallet types-including stringer pallets, skid pallets, and block pallets-the Robotic Pallet Dismantler ensures efficient, continuous pallet teardown-achieving 100 pallets per hour. Its ability to process various pallet sizes minimizes downtime, enhances productivity, and keeps pallet yards clean and organized.

By automating physically demanding tasks, the Robotic Pallet Dismantler addresses labor shortages while creating safer and more ergonomic workplaces. Employees are freed from strenuous activities and can be reassigned to higher-value roles within the company. Safety is further enhanced by a protective barrier, offering a far superior alternative to traditional manual bandsaw dismantlers.

The system is fully customizable to meet specific operational needs and spatial constraints. Key components include an operator station, infeed conveyor, powered conveyor, robotic arm with end-of-arm tooling, integrated bandsaw, RIA-standard guarding, and a vacuum system.

Alliance Automation’s team of experts provides comprehensive training, ensuring seamless operation of the Robotic Pallet Dismantler. For a fully automated solution, it can be paired with the Urban Sawmill or Badger Sawmill Series to trim and sort boards, offering unparalleled efficiency for pallet recyclers.

This revolutionary technology underscores Alliance Automation’s role as a leader in the pallet and lumber industry, providing innovative solutions that optimize operations and drive success.

 

Industrial Resources

Martin VanDenack

(616) 791-7500

sales@irinc.us

www.iresources.us

 

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, nine-inch blade and can dismantle 400-600 pallets per shift with one worker.

Features include a 64-inch-wide table, push-button table adjustment, large-diameter pneumatic drive and idler tires, and a 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.

 

PRS Group

US Toll Free: (866) 546-8864

International: (217) 291-0009

info@prsgroupinc.com

www.prsgroupinc.com

 

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: the Recycler Single and the 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.

According to PRS, PROSAW band dismantlers have become a popular, heavyweight, high-production machine. 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 provides their customers with complimentary CAD layout design and works closely with them to ensure the best reclaim system design for their specific needs.

 

Saw Service & Supply

Gary Snyder

Direct Line: (440) 785-6092

(800) 735-5604

garysnyder@sawserviceandsupply.com

www.sawservicesupply.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 airbag 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 do for you, contact Gary Snyder at Saw Service & Supply at the number listed above.

 

Smart Products

Ken Hess

(765) 284-9545

kenhess@smartproductsinc.com

www.smartproductsinc.com

 

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 eight-hour shift. Blade life, in most cases, ranges from 1,200 to 1,500 pallets. The base machines have either a 52-inch or 64-inch capacity (other larger capacity options are available). They are powered by, in most cases, either a 10 or 15 hp electric 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, electrical configurations to utilize available single-phase electrical AC voltage to power more reliable 3-phase motors, gasoline-powered engines (of multiple sizes, depending on power needed), 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 a capacity of 52 inches or 64 inches and are powered similarly to the 1-person machines with options and features that mirror their one-person styles as well.

The base Smart Products pallet dismantler system, or PDS, consists of a one-person ‘front discharge’ style dismantler dropping boards onto a 17-foot-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, doubling 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 gasoline engine (multiple sizes available) with electric start. It is available in either 52-inch or 64-inch capacity (other larger capacity options are available). This normal two-person machine can dismantle up to 700 to 800 pallets per eight-hour shift. It has many of the same features as their base electric bandsaw machines, including push-button table height adjustment, improved hydraulic blade tensioning, and durable blade guide bearings for low maintenance.

 

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 eight-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 a 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 firsthand 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 eight-hour shift.

This 3-head machine is equipped with a 15 hp motor and features a safe hand lever operation. The Trio offers a 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

BKirkaldy@woodmizer.com

www.woodmizer.com

 

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, 66-inch, 72-inch, 84-inch, or 96-inch wide table capacities. The PD200 also has 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 passback bars 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 enabling quick, convenient shifting between upper and lower cut points. This allows for easy adjustment 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.

 

Chaille Brindley

Browse Article Categories

Read The Latest Digital Edition

Pallet Enterprise February 2025