Comprehensive systems for sorting used pallets and repairing those that require refurbishing represent a significant investment, but they also can yield significant benefits for companies that recycle pallets.
They can make the work considerably faster and more efficient, increasing production. They also can provide significant ergonomic benefits to workers that reduce fatigue and injuries, aiding in production and employee retention.
Some pallet recyclers simply stage a stack of incoming pallets at each repair station, and employees have to lift them onto their table, make any necessary repairs and stack them accordingly.
Pallet sorting and repair lines typically may consist of some type of conveyor system with repair stations arranged along the line. At the start of the line, one worker may be using a tipper to singulate the pallets and grade them according to whether they need repair or can be recycled in their current condition. Some systems also use bar code stickers put on each pallet to aid in the automated sorting at the end of the line and collection of data.
Workers have a much easier job of sliding the pallet off the conveyor system onto their worktable and returning it. With some systems, the pallets are prepped earlier in the process, broken or damaged components removed, and new parts are nailed ‘on the fly’ as the pallet travels down the line.
At the end of the line, a series of stackers are arrayed to accumulate the pallets by grade. A worker may be stationed at the end of the line to designate which stacker a pallet goes to and control the process, or it may be entirely automated with the use of bar codes and a bar code reader.
Some pallet repair and sort lines may consist of a two-tier conveyor system; the second tier is used to accumulate scrap wood.
Yet another consideration is the accumulation of pallets that are not suitable for repair – whether they are processed by grinding or routed to an area to be dismantled to reclaim and recycle the used lumber.
We contacted companies that can supply complete pallet sorting and repair systems to ask what a company should consider in making this type of investment.
“We strongly recommend having an in-depth conversation with a long-standing, reputable equipment manufacturer in advance of purchasing a pallet sortation or repair system,” said Jeff Williams of PRS. “At PRS we follow an eight-step process when providing automated sort and repair systems. The first step – listen and think – is crucial in setting the strategy and perfecting the design.”
Jon Dyer of Industrial Resources offered a similar assessment. “Before requesting quotes for a pallet sorting system or repair line, evaluate the manual processes you want to replace and the improvements you expect the equipment to deliver,” he said. The processes are often labor-intensive, space-consuming, unsafe or prone to inconsistency and inaccuracy. A company also should consider how many pallets per year it expects to process. Other factors include pallet size and type mix, custom processes, customer requirements, labor needs, facility layout and growth plans.
“Reviewing these factors can identify opportunities to improve safety, quality, product flow, and throughput,” said Dyer. “The right solution is the right level of automation for your company, matching your needs today while allowing for future upgrades.” He also recommended equipment that is durable, easy to maintain and supported by an experienced manufacturer.
Dyer said, “At Industrial Resources, we understand that a first automation project may be one of the largest investments an owner makes in the business, and we take seriously our responsibility to help that investment succeed.”
“The pallet industry consists of many machines, decisions and hard work,” noted Mona Tracy of Universal Machinery Sales. “The basic machine will get the job done but adding to your existing line will get better results and reap more income.”
For example, a conveyor or round table will keep material moving and eliminate a bottleneck to production. “A stacker would be another excellent addition, so workers don’t have to stack, and the automatic eject lets the stacker do the work.”
The layout or configuration of where machines are located is very important, she noted. “Every step costs money. Stand back and look once the full line is achieved.” Alliance Automation commented about this aspect, “Space is another critical consideration, since pallet sort and repair systems require a significant footprint and must fit within the flow of the facility.” Not only evaluate your current space today but also keep in mind any changes that you may want to make as you grow or possibly even add product lines.
Any project should consider the future, not just what you need today. Alliance Automation suggested, “Before evaluating equipment, it’s important to take a step back and determine where your operation is today versus where you want it to be in one, three, and five years. Labor continues to be one of the industry’s biggest challenges, so any investment should be viewed through the lens of improving efficiency and reducing dependence on manual processes. Companies should also carefully analyze their pallet mix, including the percentage of stringer versus block pallets, the grades they handle and overall production volumes, as these factors heavily influence system design.”
Pallets should be made ready to assemble, or repair or disassemble, feeding efficiently to the appropriate conveyor or area and then to a conveyor or stacker to exit the work area. Scrap wood should be accumulated away from the production area. “A layout or plan is your key to a successful sort and repair line,” said Tracy. “Product movement is dollars saved.”
Beyond the initial quality of the machinery build, evaluate different support offerings and teams from various suppliers. Alliance Automation advised, “Choose a partner that understands your business and can guide you through the entire process, from concept and system design to installation, training, and ongoing support.”
Williams, Dyer, Tracy and Alliance Automation also contributed to the following list of questions a pallet company should consider in weighing an investment in a pallet sort and repair line. Finally, see the listings below of leading sort and repair system suppliers.
Questions to Ask
- Where is my operation today, and where do I want it to be in the future? Is the goal to improve efficiency and reduce labor? Or is it to grow and increase throughput?
- What is my biggest bottleneck? Will a sorting and repair system eliminate a constraint that’s holding the business back?
- What is your budget and your expectations for return on investment?
- What does this investment need to accomplish for your company, and what measurable results would make it successful?
- Will the supplier visit your plant to get a hands-on view of your operations?
- What is your pallet mix – conditions, grades, sizes and types?
- How much plant floor space is available?
- What machinery and equipment are required?
- What is your expected pallet volume, year 1 through year 5?
- What is your process improvement goals?
- What are my competitors doing? As the industry continues to automate, companies that stand still will fall behind.
- What happens if I don’t make a change? Will the labor and production challenges driving this decision still exist five years from now?
- What assumptions about pallet volume, customer demand, labor savings and equipment uptime must be true for the expected return on investment?
- Is this the right-sized investment for now, and can you add capacity or capabilities when the business is ready for the next step?
- Which capabilities will add real value now, and which options—such as vision inspection or data tracking—can be planned for later?
- What comparable systems can you see, and can you speak with owners who have operated them long enough to evaluate their actual throughput, durability and maintenance needs?
- How will installation and startup affect our production and employees, and what training will be provided?
- Do I have the space to support a sort and repair line? Facility layout and material flow are just as important as the equipment itself.
- Who will be responsible for the overall performance of the system, and what service and support will be available after startup?
- What is the full installed cost, including site preparation, utilities, freight, installation, training, production downtime and spare parts?
- Who is the right partner? The lowest price rarely delivers the best long-term value. Choose a partner who can support your operation, from concept through implementation and beyond.
Steps to Take
- Identify bottlenecks and heavy labor tasks that don’t add value that you would like to automate.
- Assign values to each of the tasks/functions and rank them in order. You may not be able to tackle everything at once.
- Come up with a budget based on what you can afford and finance.
- Interview various suppliers to see what each offer. Don’t be afraid to ask for references.
- Research products and options online. Start at www.palletenterprise.com.
- Visit other companies you may know to get insight and get ideas.
Suppliers
Alliance Automation
Contact: Brandon Tobias
Phone: (419) 238-2520
E-mail: info@allianceautomation.com
Alliance Automation began providing automation solutions to underserved industries in 2008. It designs and builds robotic automation systems that optimize production processes.
Alliance Automation provides pallet sort and repair systems that are easy to maintain. They increase production and up-time. These systems reduce injury probability, fatigue and workplace accidents—increasing worker longevity as well as the pool of employee candidates. Other benefits include daily production reports and remote service access. Systems can be customized with various options.
Automated Machine Systems
Contact: Kris Chayer
www.automatedmachinesystems.com
Phone: (616) 662-1309
E-mail: solutions@automatedmachinesystems.com
AMS provides cutting-edge automation solutions to the material handling, wooden pallet, and timber processing industries. It was founded in 1997 as a design and engineering firm. The company is committed to delivering service-driven solutions that help customers stay competitive in an evolving marketplace. AMS has expertise in engineering, fabrication, assembly, installation and controls; it designs, manufactures and supports its equipment entirely in-house.
AMS can supply complete pallet sort and repair systems, including equipment for sorting, accumulating and stacking pallets, pallet repair lines, pallet flippers, pallet dismantlers, and repair stations and other equipment.
Industrial Resources
Contact: Jon Dyer
Phone: (616) 791-7500
E-mail: sales@irinc.us
Industrial Resources began building custom pallet pass dismantlers and bandsaws for the pallet recycling industry in 1987. Since then it expanded to designing heavy-duty pallet sort systems, paint lines and fully customized machinery — including robotic solutions — built to withstand the abrasive demands of the pallet industry.
The company can supply systems for high-volume pallet sorting, repair and painting block and stringer pallets. It also offers wood recovery and recycling solutions to support operations of all sizes. Industrial Resources can supply single products to full systems and custom solutions for businesses of all sizes.
Pallet Repair Systems – PRS Group
Contact: Jeff Williams
Phone: (866) 546-8864
E-mail: info@prsgroupinc.com
PRS manufactures a full line of pallet equipment, including pallet stackers and dispensers, trim saws and pallet dismantlers.
The company also designs, builds, and installs complete, integrated machinery systems to automate a variety of processes. Primarily these systems are designed around three applications: pallet sortation, pallet repair and pallet recycling.
It also supplies highly automated equipment for pallet repair and recycling operations, including the Auto-Max trim saw, which scans, optimizes, and cuts and sorts pallet lumber automatically and robotic stackers and sorters.
PRS also is the exclusive U.S. and Canada representative for CAPE pallet nailing machines and automation solutions.
Pneumatico
Phone: (978) 560-3775
E-mail: sales@pneumaticousa.com
Pneumatico manufactures pallet nailing tables and repair tables. The equipment is reliable and durable, guaranteeing a high level of ergonomic comfort and efficiency. Pneumatico tables are manufactured in Europe using only the highest-quality components.
The Pneumatico WT-2 repair table features a pneumatic lift that allows for 360° rotation of the pallet and a slot for turning the pallet over. This reduces worker effort and increases productivity.
Universal Machinery Sales Inc.
Contact: Mona Tracy
www.universalmachinerysales.net
Phone: (812) 298-8090
E-mail: sales.universalmachinerysales@gmail.com
Universal Machinery Sales supplies machinery and equipment for manufacturing and repairing pallets as well as recycling used pallet lumber, including pallet nailing machines, disassemblers, sorters, stackers, trim saws and more. It can supply complete pallet sorting and repair systems.
