Pallet Control Line

Automatic checking of pallet integrity, dimensions and stability before entering the warehouse.

Technology description

The pallet control station is an automated system designed to check the integrity and suitability of empty pallets before they enter the logistics cycle. Its modular configuration can integrate different control groups, selected according to pallet characteristics and the specific requirements of the plant:

Control groups

Cleaning of pallet surfaces

The empty pallet is moved individually through the station by an integrated conveyor. During passage, a brush unit removes dust, residue and impurities from the upper and lower surfaces. The lower brushes are fixed, while the upper brush is motorised to ensure uniform and effective cleaning. Residue is directed into a removable drawer, facilitating collection and maintenance.

Nail-flattening and load-capacity check

As the pallet passes, a pneumatically operated tilting motorised roller applies controlled pressure to the upper boards, reseating or flattening any protruding nails. The treatment improves surface regularity and contributes to load stability during subsequent automatic palletising operations. Automatic pressure adjustment also makes it possible to perform a resistance test on the pallet, verifying its suitability for the loads and processes planned in subsequent stages.

Structural integrity check

Pallet integrity is checked by probing cylinders that apply controlled pressure to the upper and lower boards and to the side and centre blocks. Each element is subjected to one or more control points managed by the PLC, which detects missing, damaged or incorrectly positioned components. If anomalies are found, the pallet is classified as non-compliant and automatically directed to the reject area. The upper probing unit is installed on a pneumatically operated tilting frame designed to facilitate access during maintenance. A removable drawer finally makes it easy to collect and remove any debris.

Colour and brand recognition

A high-resolution machine-vision system identifies the pallet colour and detects logos, codes or markings on the external blocks. The acquired information makes it possible to automatically recognise and classify the different pallet types, directing them to the intended logistics flow. Using the parametric software installed on the supervisory PC, the operator can configure colour thresholds and adjust the recognition precision for lettering and marks.

Pallet length control

The PLC logic handles the compliance of the result with the machine settings.

Flatness and height control

The system detects the upper profile of the pallet, checking its overall height and surface flatness. Tolerance values configurable from the operator panel make it possible to automatically identify deformations or height differences between boards and distinguish compliant from non-compliant pallets. The control prevents instability and anomalies during automatic palletising and is particularly important when handling products with rigid support surfaces, such as totes and containers.

Fork-access control

As the pallet passes, the system checks that the fork pockets are clear and properly accessible, detecting obstacles, deformations or protruding elements. The control prevents interference with the forks and ensures a safe pick-up during subsequent automatic handling operations.

Electrical system and safety

The machine is complete with an electrical command and control panel with a Siemens PLC, an operator panel and a light tower for a visual check of the plant status. The pallet control area is safely segregated by panels and/or photoelectric barriers but accessible to operators for maintenance operations or emergency interventions.