Pallet Dispense/Stack/Insert

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Pallet Dispense/Upstack & Insert/Remove Solutions

Intelligent Pallet Flow—Delivered Exactly When and Where you Need It

Pallet availability shouldn’t slow your operation down. Kaufman Engineered Systems designs pallet dispensing, stacking, and insertion solutions that deliver, retrieve, and manage pallets seamlessly within your material handling flow—keeping your palletizing systems running without interruption.

From transfer car delivery to over-under conveyors and robotic pallet placement, our solutions are engineered to match your layout, throughput, and operational goals—ensuring pallets are always in the right place at the right time.

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Overview: Automated Pallet Control at Every Stage

Kaufman pallet handling solutions go beyond simple dispensing. We provide complete pallet flow management, including:

  • Delivering pallets into palletizing systems at precise intervals
  • Retrieving, restacking, and recycling pallets after depalletizing
  • Inserting pallets and slip sheets into load-building processes
  • Remove pallets from finished loads for customers wishing to minimize dunnage 
  • Maintain consistent spacing, alignment, and flow, supporting continuous operation with minimal manual intervention
  • Integrate with upstream and downstream systems, including palletizers and stretch wrappers
Configuration Examples
Videos
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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.

Whether pallets are moving across the facility, vertically within a system, or directly handled by robotics, Kaufman ensures a smooth, synchronized process from start to finish.

Pallet Dispense & Upstack Systems

Continuous Pallet Flow—Without Interruption

At the core of Kaufman’s pallet handling capabilities are our Pallet Dispense & Stack systems—engineered to both feed pallets into your operation and recover them for reuse in a single, continuous process. Capabilities include:

  • Dispense pallets into the palletizing flow at the required intervals
  • Receive empty pallets from downstream processes
  • Automatically upstack pallets to replenish the supply
  • Continue dispensing while restacking—eliminating interruptions
ImageAbout Kaufman Engineered Systems

Kaufman Pallet Dispense & Stack system, lifting a stack of pallets in order to release the bottom pallet into the palletizing stream. 

Why It Matters

This dual-function capability allows your system to:

  • Operate with fewer total pallets in circulation
  • Maintain continuous production without manual intervention
  • Eliminate bottlenecks between palletizing and depalletizing processes
  • Improve overall system efficiency and throughput

Flexible Configuration Options

Kaufman Pallet Dispense & Upstack units can be configured to interface with your system layout:

  • Pallet infeed/outfeed from the front
  • Pallet delivery and retrieval from the rear
  • Side-entry configurations for tight or complex layouts

This flexibility ensures seamless integration regardless of facility constraints.

Additional Pallet Dispensing Solutions

Multiple Methods with One Goal—Uninterrupted Production

Different operations require different approaches to pallet delivery. Kaufman offers several dispensing methods—each designed to maximize efficiency based on your layout and throughput needs.

Transfer Car Pallet Delivery & Retrieval

Flexible, long-Distance Pallet Movement

Transfer cars provide a highly flexible way to move pallets across long distances or between multiple lines. Pallets can be delivered to or retrieved from palletizing systems without disrupting surrounding operations.

Value:

  • Ideal for facilities with multiple palletizing or depalletizing zones
  • Enables centralized pallet storage with distributed delivery
  • Reduces forklift traffic and improves safety
  • Supports bidirectional flow (delivery and return)
Transfer Car Details
ImageAbout Kaufman Engineered Systems

Kaufman Transfer Car Conveyor Delivering a Palletized Load, while Feeding an Empty Pallet to a Dispense & Stack Unit to be Recycled Into Use. 

High-Low Conveyor Systems

Efficient Over-Under Pallet Flow

High-low conveyor systems use an upper and lower conveyor path to deliver pallets into the system and return them after use—creating a continuous loop.

Value:

  • Maximizes floor space efficiency
  • Provides continuous pallet recirculation
  • Reduces congestion on primary conveyor lines
  • Ideal for high-throughput operations with consistent pallet reuse
ImageAbout Kaufman Engineered Systems

Low Conveyor Delivers Pallets, Lifted Onto the Conveyor for Robot to Build the Load, Sent Upstream When Finished, and Process Repeats. 

Robotic Dispensing

Precision Placement with Maximum Flexibility

In robotic pallet dispensing systems, a robot retrieves a pallet from a storage area, places it into position, optionally places a slip sheet, and then begins palletizing.

Value:

  • Enables multi-function automation (pallet placement + sheet placement + palletizing + top cap/top sheet)
  • Highly flexible for mixed product lines or variable patterns
  • Reduces dedicated equipment by consolidating functions
  • Ideal for operations already leveraging robotic palletizing (KPal® systems)

Depending on the application and customer requirements, one or more of these robotic dispensing features is often built into our KPal Robotic Palletizing Solutions.

KPal Palletizing Series
ImageAbout Kaufman Engineered Systems

KPal K5 Full Layer Palletizing System with IR Vision for Dispensing Pallet, Bottom Sheet, Slip Sheets Between Layers After Building, and Protective Top Cap to Finished Loads.  

Additional Pallet Stacking Solutions

Organized Recovery and Reuse of Pallets

Pallet stacking is just as critical as dispensing. Kaufman systems ensure pallets are efficiently collected, aligned, and restacked for reuse—keeping your operation clean, organized, and ready for continuous flow.

Stacking via Transfer Cars, Conveyors, Robotics, or Dispense & Stack Systems

The same methods used for pallet dispensing can also be applied to stacking:

  • Transfer Cars: Retrieve pallets from multiple points and return them to a central stacking location
  • High-Low Conveyors: Automatically route empty pallets back through a return loop
  • Robotic Handling: Pick and stack pallets with precision and adaptability
  • Dispense & Stack Systems: Can be used to up-stack pallets as well as dispense them

Value Across All Methods:

  • Reduces manual handling and labor dependency
  • Improves plant organization and pallet inventory control
  • Minimizes downtime caused by pallet shortages
  • Enhances safety by limiting forklift interaction
ImageAbout Kaufman Engineered Systems

Robotic Pallet Stacking cell with FANUC Robot and Load Lift Conveyor Building Stacks of 9 Pallets. 

 

 

 

Pallet Removal Solutions

Deliver Finished Loads—Without the Pallet

In many operations, pallets are essential for internal handling—but unnecessary or even undesirable at the final destination. Some customers require loads to be delivered without pallets to eliminate the need to manage, store, or dispose of dunnage within their facility.

Kaufman provides solutions that enable manufacturers to automatically remove pallets from fully built loads prior to shipping, ensuring products arrive exactly as required by their end customers.

ImageAbout Kaufman Engineered Systems

System Utilizing a Load Pusher to Remove the Pallet from a Finished Load of Stacked and Wrapped Product.

Why Remove Pallets Before Shipping?

For many manufacturers, pallet removal isn’t just a preference—it’s a requirement driven by downstream efficiency.

Customer-Driven Benefits:

  • Eliminates the need for pallet handling at the receiving facility
  • Reduces clutter, storage needs, and disposal requirements
  • Supports facilities with automated or pallet-free receiving systems
  • Improves overall supply chain efficiency

Pallet Insertion Solutions

Supporting Stable, Protected Loads

In addition to dispensing and stacking, we have the ability to incorporate Load Lifting Conveyors, Load Lift & Square units and Load Pushers into systems that require a pallet be inserted under fully finished loads.

Kaufman systems can insert: 

  • Pallets beneath loads
  • Slip sheets between layers or beneath loads

This ensures loads are properly prepared for: 

  • Stretch wrapping
  • Storage
  • Transport
ImageAbout Kaufman Engineered Systems

System with Load Lift Conveyor, Load Lift & Square Unit, and Automatic Backstop to Raise Load, Allowing Pallet to be Conveyed and Stopped Directly Under the Load. The Load Lift & Square Unit then Gently Places the Load On the Pallet.  

Why Insert Pallets Under Finished Loads?

While some operations remove pallets before shipment, many require pallets to be precisely inserted beneath finished loads to ensure they can be handled, transported, and stored efficiently. Pallet insertion often plays a critical role in bridging the gap between load formation and downstream logistics, ensuring every load is properly supported before it leaves the system.

Pallet insertion is especially valuable in operations where:

  • Loads are built directly on conveyors or slip sheets
  • Products require secure handling prior to shipping
  • Facilities rely on forklifts or pallet-based transport systems
  • Consistency and alignment are critical for downstream automation

Pallet Handling Configuration Examples

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Pallet Dispense & Upstack and Pallet Insertion Videos

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The Kaufman Advantage

Engineered for Complete System Integration

Kaufman pallet handling solutions are designed to integrate seamlessly with:

  • Robotic palletizing systems (KPal® series)
  • Stretch wrapping systems (Rotary Arm, Turntable, Horizontal Ring)
  • Conveyor systems and transfer cars
  • Dual load stackers and other material handling solutions

Using advanced controls and system synchronization, we ensure every component works together to maintain flow, efficiency, and reliability.

When to Consider a Pallet Handling Solution

You may benefit from automated pallet dispensing and stacking if your operation is experiencing:

  • Inconsistent pallet availability
  • Manual handling slowing production
  • Excess pallet inventory requirements
  • Bottlenecks between palletizing and downstream processes
  • Increased safety risks from forklift traffic

With over 80 years of engineering expertise, Kaufman delivers pallet handling systems that are:

  • Built for real-world industrial performance
  • Designed for seamless integration
  • Backed by advanced simulation and system validation
  • Engineered to scale with your operation

From robotic pallet dispensing to fully integrated dispense-and-stack systems, Kaufman delivers solutions that keep your operation moving—efficiently and continuously.

Contact our team today to discuss your application and requirements.

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