Pallet Handling Conveyor Systems

Professional Pallet Conveyor Design, Installation

Pallet handling conveyor systems transport wooden pallets, plastic pallets, and skids throughout manufacturing and warehouse operations, integrating with palletizers, stretch wrappers, and automated storage systems. We design and install complete pallet conveyor networks using chain-driven roller, heavy-duty belt, and transfer technologies engineered for reliability, durability, and integration with your material handling automation.

Pallet Conveyor Types, Configurations

Chain-Driven Live Roller (CDLR): Heavy-duty powered roller conveyor using chain linkage to drive steel rollers. 2-strand or 3-strand chain configurations handle loads from 500 to 6,000 lbs per pallet. Roller diameters from 1.9" to 3.5" with heavy-duty ball bearings. Frame widths from 42" to 60" accommodate standard pallet sizes. Speeds adjustable from 15 to 120 feet per minute. Ideal for continuous pallet transport, accumulation zones before stretch wrappers, and integration with automated storage and retrieval systems.

Chain Transfer Conveyors: Parallel chains mounted flush with roller surface pop up to transfer pallets 90 degrees onto perpendicular conveyor lanes. 2-strand or 3-strand chain transfers handle various pallet conditions. Transfer cycles typically 3 to 8 seconds depending on pallet weight and chain speed. Essential for multi-lane sortation, dock door distribution, and compact facility layouts requiring directional changes without manual handling.

Heavy-Duty Belt Conveyors for Pallets: Wide belt conveyors with reinforced frames transport pallets in applications where roller gaps are problematic or smooth surface is required. Belt widths from 36" to 60" with heavy-duty rubber or PVC belting. Handles damaged pallets, partial loads, and non-standard pallet sizes that may catch on roller gaps. Incline and decline capabilities for elevation changes.

Pallet Turntables: Rotating platforms reorient pallets for ergonomic access or directional changes without transfer conveyors. Diameters from 48" to 84" with load capacities 2,000 to 6,000 lbs. Powered rotation with adjustable speed and positioning. Common applications include end-of-line pallet orientation for stretch wrapping, palletizer discharge alignment, and fork truck loading station access.

Pallet Stops, Positioning, Controls

Pallet Stop Mechanisms: Pneumatic or electric pallet stops raise to halt pallet movement for accumulation, inspection, or process integration. Integrated with photo-eyes for automatic pallet detection. Heavy-duty construction withstands repeated pallet impacts. Release signals from PLC controls or manual buttons.

Centering Guides: Side guide rails with spring-loaded or powered adjustment center pallets for downstream equipment such as stretch wrappers, automated guided vehicles, or robotic pick systems. Squaring mechanisms align skewed pallets before transfer or processing.

Load Measurement Systems: In-line scales weigh pallets during transport for inventory management, shipping documentation, or process verification. Integrated with conveyor controls to stop pallets during weighing for accuracy.

Pallet Stackers, Destackers

Pallet Dispensers: Automated pallet stackers store and dispense empty pallets to production or packaging lines. Magazine-style storage holds 15 to 50 pallets. Hydraulic or pneumatic elevation raises stack as pallets are dispensed. Photo-eyes detect pallet presence and signal low stack conditions.

Pallet Destackers: Automated systems separate individual pallets from incoming stacks for distribution to multiple lanes or work stations. Vacuum or mechanical grippers lift top pallet while stack is lowered. Integrate with conveyor systems for continuous pallet feeding.

Integration with Material Handling Equipment

Stretch Wrapper Integration

Pallet conveyors integrate with automatic stretch wrappers for complete end-of-line packaging. Conveyors transport pallets to wrapper infeed, wrapper turntable rotates load while film dispenser applies stretch wrap, then discharge conveyors transport wrapped pallets to shipping or storage. Accumulation zones buffer pallets before and after wrapping. PLC controls coordinate wrapper cycles with conveyor flow.

Palletizer Discharge Conveyors

Heavy-duty conveyors receive completed pallet loads from robotic or conventional palletizers. Discharge conveyors transport loads to stretch wrappers, pallet strapping machines, or shipping lanes. Turntables reorient pallets for optimal wrapper entry or fork truck access.

Dock Door Distribution

Multi-lane pallet conveyor systems with chain transfers sort pallets to specific dock doors based on shipping destination or carrier routing. Barcode scanning identifies pallet destination, PLC controls activate transfers to divert pallets to correct lanes. Accumulation conveyors buffer pallets at each dock door for truck loading.

Automated Storage Integration

Pallet conveyors feed automated storage and retrieval systems (AS/RS) with precise positioning for automated crane pickup. Retrieval conveyors transport pallets from AS/RS to order picking, cross-docking, or shipping operations. Dimensional scanning verifies pallet height before AS/RS induction to prevent rack damage.

Applications, Use Cases

End-of-Line Packaging: Palletizer discharge with conveyors transporting completed pallet loads to stretch wrappers, accumulation before wrapping to buffer production surges, wrapped pallet transport to shipping lanes or storage, and pallet labeling integration for shipping documentation.

Warehouse Shipping, Receiving: Receiving dock conveyors transporting pallets from trucks to put-away locations, cross-dock operations with transfer conveyors routing pallets from receiving to shipping, shipping lane distribution with chain transfers sorting pallets to specific dock doors, and pallet accumulation zones buffering loads during truck loading.

Manufacturing Operations: Work-in-process pallet transport between production cells, pallet inverters rotating loads for bottom access or damaged pallet replacement, finished goods conveyors linking production to warehouse or shipping, and accumulation zones decoupling production from packaging for continuous manufacturing flow.

Pallet Conveyor Specifications

Load Capacities, Speeds: Standard CDLR systems: 500 to 4,000 lbs per pallet, speeds 15 to 90 FPM. Heavy-duty systems: 4,000 to 6,000 lbs per pallet, speeds 15 to 60 FPM. Chain transfers: 500 to 6,000 lbs capacity, transfer cycles 3 to 8 seconds. Belt conveyors: 500 to 3,000 lbs per pallet, speeds 20 to 100 FPM.

Pallet Sizes, Frame Widths: Standard frame widths accommodate 40" x 48", 42" x 42", and 48" x 48" pallets. Common widths: 42", 48", 54", 60". Conveyor lengths from 5 feet to 100 plus feet with multiple drive units for long runs. Incline and decline capabilities up to 10 degrees for elevation changes.

System Controls, Safety

Pallet conveyor systems integrate with programmable logic controllers (PLCs) for automated sequencing and routing. Photo-eye sensors detect pallet presence and position, barcode scanners identify pallet destinations for sortation, and safety systems include emergency stop pull-cords, light curtains at transfer points, and guarded nip points. Interface protocols include Ethernet/IP, DeviceNet, and Modbus for integration with warehouse management systems and enterprise software.

Maintenance, Support Services

Our service team provides chain tension adjustment, roller bearing replacement, transfer chain servicing, and motor repairs. Preventive maintenance programs include lubrication schedules, alignment checks, and wear component inspection. We stock replacement chains, rollers, and drive components for rapid response throughout the Northeast & Mid-Atlantic region. Emergency repair services minimize production downtime and keep material flowing.

Complementary Automation

Frequently Paired Solutions

Pallet handling systems deliver maximum efficiency when integrated with these warehouse solutions:

Industries We Serve