Pallet Automation
Fast, reliable, fully automated Pallet solutions
Pallet Conveyors
Efficient, safe movement of palletised loads is fundamental to high‑performing operations. Our pallet handling solutions combine heavy‑duty conveyors, intelligent transfers, and integrated controls to deliver predictable flow, reduced manual handling, and faster turnarounds, from production outfeed to despatch and AS/RS interface.
Our pallet conveyor systems are ideal for:
- Feeding to and from production or finishing areas
- Integrating with automated storage and retrieval systems (AS/RS)
These systems typically utilise roller or chain-based conveyors, ensuring reliable and consistent pallet movement.
Capabilities & Safety
We design and integrate roller and chain conveyors up to 2,000 kg per pallet, with turntables, right‑angle transfers, and lift‑lower stations for complex routing. Systems are engineered for 60–180 pallets/hour, tailored to your pallet mix, environment, and upstream/downstream equipment. Controls include PLC/HMI, safety PLC zoning, and WMS/WCS handshakes with barcode or RFID identification.
Every system is delivered with CE marking, guard plans,emergency stop circuitry, and training. For cold stores and hygiene‑critical
areas, we offer galvanised or stainless designs, sealed bearings, IP‑rated devices, and low‑temperature components.
Pallet Conveyors uses
Inbound & Receiving: Pallet receiving, identification, weighing, dimensioning, label application; queue management before putaway.
Production Infeed/Outfeed: Line‑side supply, empty pallet return, WIP buffers, full pallet discharge.
Packing & Despatch: Accumulation lanes, order consolidation, stretch‑wrapper integration, dock interfaces.
Cold Chain & Food: stainless or galvanised options, low‑temperature components, wash‑down designs.
High‑Bay & AS/RS Interface: pallet staging for cranes/shuttles; hand‑off with WCS.
Pallet Conveyors can help reslove...
Production bottlenecks caused by inefficient pallet movement
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Inconsistent pallet flow between manufacturing, storage, and dispatch areas
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Damage to goods caused by uncontrolled or uneven pallet handling
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Labour-intensive forklift traffic and congestion on the warehouse floor
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Limited throughput and poor utilisation of available space
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Difficulty integrating pallets with automated storage or production systems
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Lack of visibility and control over pallet movements within operations
Advantages of Automated Pallet Systems
Implementing automated pallet systems offers several key advantages for your operations, including:
- Increased Efficiency by streamlining loading and unloading operations, reducing transport times and enabling a constant product flow.
- Enhanced Safety by minimising workplace injuries by reducing manual handling.
- Cost Saving efficiency by lowering labor costs and minimises product damage through precise movement and positioning.
- Accommodates a wide range of pallet sizes and weights, suitable for various industries and applications.
Our pallet conveyor solutions
Our pallet conveyor solutions can incorporate equipment such as:
- Lifts / Elevators
- Wrappers / Hooders / Strappers
- Palletisers
- Accumulation roller conveyors
- Pallet dispensers/stackers
- ASRS systems
- Pallet condition checks, including weigh stations
- AGV’s
modular pallet design
- Improved throughputs – more products moved per hour
- Reductions in labour requirements and MHE costs
- Constant movement of products/materials between sectors
- Significant reduction in health and safety risks
- Quickly and safely move products between floor levels
Discuss your automation Project
Thank you for your interest in CSL Automation. As one of the UK’s leading conveyor and automation integrators, we can help design and install a system to help you take your business to the next level.
Start your automation journey today.
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Frequently Asked Questions
How versatile are conveyor solutions for different pallet sizes?
Highly versatile! We cater to most pallet and cage sizes and weights, ensuring consistent and smooth operations irrespective of the load.
What's the advantage of opting for automated storage/retrieval alongside conveyors?
Automated storage and retrieval systems (AS/RS) combined with our conveyors provide a fully integrated solution, maximising storage space, ensuring quicker retrieval times, and streamlining the entire logistics process.
Do you provide maintenance services for installed conveyor systems?
Yes, in addition to our state-of-the-art systems having lower maintenance requirements, we also offer maintenance services to ensure your conveyors run optimally.
How do pallet condition checks enhance the conveyor system?
By automatically assessing and filtering out compromised pallets, we prevent potential disruptions and damages, ensuring a smoother flow and longer lifespan for the system and the products.
Can I get a customised solution for my specific needs?
Certainly. We pride ourselves on offering modular solutions for general needs and bespoke designs tailor-made for specific requirements.
Can you handle mixed pallet sizes and plastic pallets?
Yes, adjustable guides, sensor ranges, and chain conveyors for non‑standard bases.
How do you integrate with our WMS/WCS?
Barcode/RFID identification, hand‑shakes via standard protocols, PLC/WCS middleware, and diagnostic dashboards.
What’s the typical ROI?
12–24 months depending on labour elimination, throughput gains, and safety benefits; we provide an ROI model.
What guidance does CSL Automation provide on pallet construction, tolerances and condition?
CSL Automation provides clear pallet specification guidance during the design phase to ensure reliable and safe operation of automated systems. This includes recommended pallet dimensions, load tolerances, deck board spacing, runner orientation, and material quality.
We also advise on acceptable levels of pallet wear, including limits on damaged or missing boards, protruding nails, and warping. Where required, systems can be designed with additional sensing, guides, or pallet handling features to accommodate known pallet variations. Clear pallet standards help reduce downtime, prevent equipment damage, and maintain consistent system performance.
How does CSL Automation handle poor pallet quality within automated systems?
Poor pallet quality is a common challenge in automated environments, and CSL Automation designs systems to minimise its impact wherever possible. Depending on the application, solutions may include pallet inspection points, reject lanes, alignment mechanisms, controlled transfer methods, or pallet repair and replacement processes upstream.
Where pallet quality cannot be fully controlled, CSL works closely with customers to define acceptable tolerances and implement mitigation measures that protect both equipment and throughput. Our approach focuses on maintaining operational continuity while reducing the risk of jams, product damage, and unplanned downtime.
We also advise on acceptable levels of pallet wear, including limits on damaged or missing boards, protruding nails, and warping. Where required, systems can be designed with additional sensing, guides, or pallet handling features to accommodate known pallet variations. Clear pallet standards help reduce downtime, prevent equipment damage, and maintain consistent system performance.
More Infomation
What are pallet automation & conveyor systems?
Pallet conveyor systems are built to streamline pallet movement and management. Our automation ensures pallets, whether empty or loaded with up to 2 tons, move seamlessly and safety throughout your facility.
The primary function of a pallet conveyor is to effectively move goods. This could be between production, finishing zones, storage areas, and more. Often they can eliminate the need for manual handling or forklift truck which reduces error and potential injury to your workforce.
They can be installed with complementary equipment like wrappers, strappers, and labellers. All of which are pivotal in progressing towards a fully automated and efficient facility.
Pallet Racking
Conveyor Systems Ltd.’s expertly designed pallet racking and shelving systems bring precision and adaptability to your storage needs. Whether considering new installations or enhancing existing setups, our pallet rack mezzanine solutions cater to your unique requirements, including product type, stock life cycle, throughput, and compatibility with retrieval and replenishment machinery.
Pallet Racking Mezzanine Systems:
Choose from an array of pallet racking options meticulously designed for optimal storage efficiency:
- Wide aisle: Offering versatile access to your goods, suitable for various product types and stock cycles.
- Narrow aisle: Ideal for high-density storage, maximising vertical space utilisation.
- Double deep: Doubling storage capacity while maintaining selectivity.
- Drive in/through: High-density storage with fewer aisles, perfect for bulk goods.
- Push back: Maximising space while allowing for efficient stock rotation.
- Pallet line storage: Systematically streamlining storage.
The benefits of automating pallet movement
- Hybrid & full automation: Seamless integration options, whether partial or fully automated, to work effectively with AGVs
- Smart System integration: Our advanced control systems (WCS) work with the client’s WMS, promoting an intelligent operational approach
- Increased safety: Reduction in forklift movements for an enhanced safety profile for your facility
- Optimal labour utilisation: With automated pallet transit, harness the full potential of your workforce, directing labour resources more strategically
- Consistent pallet movement: Ensure uninterrupted pallet transit and feeds
- Flexible pallet accumulation: Options for both live and offline pallet accumulation
- Versatility in handling: Our systems accommodate various pallet and cage weights and sizes
- Economical maintenance: In the long term, our automated systems are more cost-effective, requiring less upkeep than forklift trucks.
Our Pallet Conveyor Solutions
Accumulation roller conveyors
These systems allow for the temporary storage of pallets by halting or accumulating them in designated zones. This is done without interrupting the flow or requiring a stop in the conveyor line. It ensures a smoother workflow, beneficial in areas with different pallet processing speeds.
Whether integrating into production zones, finishing areas, or automated storage/retrieval systems, these conveyors excel in harmonising transitions. Our designs ensure compatibility with both single empty pallets and heavier 2-ton loads. This can offer flexible solutions for modern warehousing needs.
Elevators and lowerators
Elevators and lowerators make the most of vertical space and ensure smooth movement of pallets across different levels such as mezzanine floors.
With our innovative design, they integrate within our conveyor solutions, ensuring pallets transition smoothly, even in height-restricted environments. We can integrate elevators and lowerators within our conveyor solutions, ensuring pallets transition smoothly, even in height-restricted environments.
Palletisers
Palletisers arrange goods onto pallets in predefined patterns, so they are ready for distribution or storage. Palletisers integrate with your conveyor systems ensuring an easy transition from production lines to complete pallet loads.
Palletisers can maximise storage, increasing throughput, and reducing manual handling risks.
Pallet condition checks
Pallet condition check systems can detect any damages or irregularities in pallets before they enter the automation flow. Our integrated systems ensure that only pallets in prime condition progress through the conveyor system. This proactive approach safeguards the goods and prevents potential system disruptions while also reducing health and safety risks.
By automatically assessing and filtering out compromised pallets, operational efficiency is enhanced, reduce manual oversight, and ensure the longevity of both products and the automated system itself.
Chain Conveyors
Chain Conveyors are powered chains set in tracks. They are engineered to transport heavier loads, like substantial pallets, with ease and precision.
Whether directing goods between production zones or streamlining pathways to storage areas, they are incredibly versatile and work well with other equipment, like palletisers and wrappers.
