Automated Pallet Inspection and Sorting System with Robotic Handling
When pallets enter your production or packaging line, defects such as broken boards, protruding nails, or contamination can cause line stops and product damage. An automated pallet inspection and sorting system allows you to detect and remove defective pallets before they disrupt operations.
Inspect and sort pallets using robotic handling and vision systems
The automated pallet inspection and sorting system from Ferrum Group uses robotic handling combined with advanced vision technology to inspect pallet condition and sort pallets based on predefined quality criteria. The system is designed to prevent production downtime by ensuring that only compliant pallets enter the line.
Pallet stacks are fed into the system, where a robot separates and transports individual pallets through an inspection station. The inspection process is performed using high-resolution camera systems, including up to 8 integrated 3D cameras, which analyse the pallet structure, surface condition, and potential defects.
The system can detect issues such as damaged boards, contamination, and structural defects, and optionally evaluate parameters such as colour and humidity. Based on the inspection results, pallets are automatically sorted into different categories (e.g. approved, rejected, or rework), and stacked accordingly.
For systems equipped with a nail press unit, protruding nails are automatically corrected during processing, reducing the need for manual repair. An integrated brush system removes dirt from pallet surfaces, improving hygiene in food and beverage environments.
Different configurations are available depending on required capacity and functionality. Standard systems such as Palletscan 100 and 100 PLUS operate at 80–120 pallets per hour, while higher-capacity systems such as Palletscan 240 reach up to 240 pallets per hour. Solutions can also include top frame sorting and integration with pallet conveyors and buffer systems.
The system is controlled via a Siemens S7 HMI interface, allowing a single operator to monitor performance, track sorted pallet quantities, and manage system settings. It integrates with upstream pallet supply and downstream palletising or filling operations, ensuring continuous material flow.
By automating pallet inspection and handling, the system reduces manual labour, increases throughput, and improves overall line reliability.
Benefits
- — Prevents production stops caused by defective pallets
- — Automated inspection using up to 8 integrated 3D cameras
- — Sorts pallets into quality categories at up to 240 pallets/hour
- — Reduces manual handling and pallet inspection effort
- — Improves hygiene with integrated cleaning and nail correction