Dual Load Stackers
Dual Load Stackers
Enhancing Efficiency in Material Handling
In modern manufacturing and warehousing operations, efficiency, reliability, and precision are critical to maintaining productivity and meeting demand. Dual Load Stackers play a pivotal role in automated material handling, enabling businesses to streamline operations, reduce manual labor, and maximize throughput.
At Kaufman Engineered Systems, we specialize in designing and integrating high-performance dual load stackers into complete end-of-line automation solutions. Our engineered systems help customers overcome key challenges in palletizing, product stacking, and material conveyance, driving measurable operational improvements.
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Discover what Kaufman Engineered Systems can do for your business. Contact our award-winning account managers today for a consultation: info@KES-USA.com or 419-878-9727.
Kaufman Dual Load Stacker Series
Kaufman Offers Two Models You Can Choose From: Side-Entry and Inline
While both models achieve the same core objective—automated dual-load stacking—their mechanical approaches serve different operational needs.
| FEATURES | SIDE-ENTRY STACKER | INLINE STACKER |
|---|---|---|
| Product Flow | Maintains forward flow with side lift mechanism | Fully vertical lift |
| Layout Flexibility | Ideal for heavy loads | Ideal for lighter loads |
| Space Utilization | Right angle to flow | Optimal for tight floor plans |
The ideal dual load stacker configuration depends on your load characteristics, available floor space, and overall system layout. Side-entry stackers are often preferred for heavier loads and applications where positioning the stacker perpendicular to the conveyor line provides greater layout flexibility. Inline stackers are typically well-suited for lighter loads and facilities where a straight-line configuration maximizes the use of available floor space.
Both designs can be custom-engineered to accommodate specific load sizes, throughput requirements, and upstream automation equipment. For pallet-free operations, side-entry stackers can handle slip-sheet loads without pallets and can also be configured to insert a pallet beneath completed double-stacked loads as a secondary operation when required.
Side-Entry Dual Load Stacker
Kaufman's Side-Entry Dual Load Stacker is designed for applications requiring the stacking of heavier palletized loads. In this configuration, the first load enters and is stopped precisely in front of the stacker. It is then elevated by a fork-tyne lifting mechanism that enters from the side. A second load is then conveyed into position beneath the raised load before the upper load is carefully lowered to complete the stack.
This design is particularly effective for facilities where:
- Heavy loads require stable, reliable double-stacking
- Layout flexibility allows equipment to be positioned perpendicular to the conveyor line
- Slip-sheet loads or pallet-free operations are utilized
- Automated stacking can reduce forklift traffic, product handling, and labor requirements
The side-entry design can also be configured to allow single loads to pass through when double stacking is not required, providing flexibility for operations handling multiple product types. In pallet-free applications, the system can additionally be used to insert pallets beneath completed double-stacked loads as a secondary operation. Whether integrated into an existing line or installed as a standalone solution, side-entry dual load stackers can deliver significant operational efficiencies while minimizing manual load handling.
Inline Dual Load Stacker
Kaufman's Inline Dual Load Stacker performs the same double-stacking function within a compact, straight-line conveyor configuration. The first load enters, stops precisely aligned with the stacker, and is raised vertically while a second load advances beneath it. Once the second load is properly positioned, the upper load is placed gently on top of the lower load to complete the stack before continuing downstream.
This configuration is ideal for:
- Lighter palletized loads
- Facilities with limited available floor space
- Applications requiring efficient use of existing conveyor footprints
- Automated stacking can reduce forklift traffic, product handling, and labor requirement
Because the stacking mechanism is built directly over the conveyor path, the inline design minimizes the overall system footprint while providing reliable automated load stacking. For operations where floor space is at a premium and load weights are well-suited to vertical lifting, inline dual load stackers offer an efficient and cost-effective solution for increasing storage density and shipping efficiency.
Dual Load Stacker Videos
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KForce T20 with Hold Down, Robotic Labeler, and Dual Load StackerClick Here to Open Full Screen
Dual Load Stacker with Pallet InsertionClick Here to Open Full Screen
Side-Entry Dual Load Stacker with Two Pairing StationsClick Here to Open Full Screen
Inline Dual Load Stacker Followed By Lowering ConveyorClick Here to Open Full Screen
Heavy Duty Dual Load Stacker with Side-EntryClick Here to Open Full Screen
Heavy Duty Side-Entry Dual Load StackerClick Here to Open Full Screen
Inline Dual Load StackerClick Here to Open Full Screen
Automatic Heavy Duty Load StackerClick Here to Open Full Screen
What ARE Dual Load Stackers?
A dual-load stacker is an automated material handling system designed to receive, align, and stack two product loads simultaneously in a controlled, repeatable sequence. Unlike manual stacking with forklifts—where operators must pick, position, and place individual loads one at a time—a dual-load stacker performs the process with precision timing, synchronized controls, and consistent load placement.
For manufacturers looking to improve efficiency, safety, and overall equipment effectiveness (OEE), dual-load stackers replace reactive, labor-dependent processes with engineered precision. The result is a cleaner flow of product, better utilization of floor space, and a stacking operation designed to support long-term growth—not limit it.
Close-up of the heavy-duty lift drive train on one of our dual load stackers.
HOW DUAL LOAD STACKERS WORK
1. Product Loading - finished loads are fed into the stacking station via a conveyor system or robotic palletizer.
2. Dual-Load Processing - The system lifts one load so another can be conveyed directly underneath, ensuring the two loads are fully aligned.
3. Precision Stacking - Using sensors and automation technology, the stacker precisely places each load with consistent alignment and secure positioning.
4. Discharge & Integration - Once stacked, the loads are conveyed to the next phase of the automation system, such as robotic labeling or off-loading for storage and/or distribution.
The value of this automation becomes clear in high-volume environments. Manual forklift stacking introduces variability in alignment, stack height, and cycle time, requiring labor, creating traffic congestion on the plant floor, and increasing the risk of product damage or safety incidents. In contrast, a dual-load stacker delivers consistent load alignment, creates predictable cycle times, and minimizes both damage and safety risks.
CHALLENGES SOLVED BY DUAL LOAD STACKERS
1. Increased Throughput Demands - With rising consumer demand and just-in-time manufacturing, companies must find ways to increase output without expanding their footprint. Dual-load stackers provide twice the stacking capacity with the same cycle time as single-stack units, enabling higher throughput and efficiency.
2. Reducing Manual Labor & Safety Risks - Manually stacking heavy loads is not only labor-intensive but also poses a risk of workplace injuries. Dual load stackers eliminate the need for manual lifting, reducing worker fatigue and improving overall plant safety.
3. Maintaining Stacking Consistency & Quality -Stack misalignment can lead to product damage, unstable pallet loads, and inefficiencies in downstream operations. Kaufman’s precision-engineered stackers use advanced sensors and automation controls to maintain uniform stacking, ensuring a secure, consistent load every time.
4. Space Optimization in Warehousing & Distribution -In high-density storage environments, maximizing space is crucial. A dual load stacker allows more product to be stored in a structured, stable manner, reducing footprint requirements and enhancing warehouse organization.
Why Companies Choose Kaufman Engineered Systems
Kaufman Engineered Systems has been a trusted leader in material handling automation for 80 years, delivering custom-engineered solutions that maximize productivity, safety, and efficiency.
What Sets Kaufman’s Dual Load Stackers Apart?
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Custom Engineered for Your Application – Designed to fit your unique material handling requirements, including varied load sizes, weights, and production speeds.
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Seamless System Integration – Our stackers integrate directly into robotic palletizing, stretch wrapping, and conveyor systems, providing a fully automated material handling solution.
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Robust, Industrial-Grade Design – Built for heavy-duty, high-speed manufacturing environments, ensuring long-term reliability and minimal maintenance.
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Advanced Automation & Smart Controls – Featuring PLC-based programming, sensor-guided alignment, and real-time monitoring for optimized performance.
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End-to-End Support – From design and engineering to installation, training, and maintenance, Kaufman ensures seamless implementation and long-term success.
