12.9.2025 / 5-minute read

Pallet Inverter Solves Bottleneck for Automated Warehouse Integration

Overview

A large home goods distributor operating a modern Automated Storage and Retrieval System (ASRS) warehouse faced a critical operational bottleneck.

Their inbound logistics required the removal of thin wooden layer boards (slip sheets) from between the tiers of goods on full pallets.

This step was essential before pallets could enter the fully automated system, as the boards would interfere with the ASRS machinery.

Basic Parameters

Load Capacity	Up to 1,500 kg
Pallet Size	800×1200 mm to 1200×1600 mm
Max. Load Height	2,200 mm
Cycle Time	90-120 seconds
Rotation	90°
Footprint	~4.5 x 3.5 m
Control & Integration	PLC, PROFINET/Ethernet/IP

Challenge

High Labor Intensity & Low Efficiency: Workers had to manually de-stack or awkwardly remove boards, significantly slowing down the receiving process.
Significant Safety Risks: Handling heavy goods and boards posed ergonomic injury risks and potential for loads to collapse.
Product Damage: Manual handling increased the risk of damaging goods during board extraction.
Process Disruption: This manual step created a major choke point, preventing seamless flow from the receiving dock to the high-speed ASRS.

Solution

Automatic Induction & Clamping: A full pallet is conveyed directly into the pallet inverter’s station. The unit’s arms automatically and securely clamp the entire load from all sides.
90-Degree Safe Rotation: The clamped load is smoothly and precisely rotated 90 degrees to a stable vertical position. This patented flipping action keeps all goods perfectly intact.
Ergonomic Board Removal: In the vertical position, workers now have safe, ergonomic access to all sides of the load. All inter-layer boards can be quickly and easily removed without strain or risk.
Automatic Reset & Conveyance: Once cleared, the inverter rotates the stabilized pallet back to its original horizontal position. The board-free pallet is then automatically conveyed to the ASRS infeed station, ready for storage.