Automated Pallet Stacking
Pallet stacking and retrieval is the most repetitive, physically demanding, and error-prone task in warehouse operations. Autonomous forklifts stack pallets with millimetre precision at heights up to 9 metres — consistently, safely, and around the clock — eliminating the racking damage, product drops, and operator injuries that plague manual stacking operations.
The Manual Stacking Problem
Manual pallet stacking at height is one of the most dangerous warehouse activities. Even experienced operators face challenges:
- Racking damage — Australian warehouses spend an estimated $2 billion annually on racking repairs caused by forklift impacts
- Height limitations — manual operators become less accurate above 5-6 metres; many sites limit manual stacking to lower levels
- Fatigue degradation — stacking accuracy drops 15-25% over a shift as operators fatigue from constant head-tilting and precise manoeuvring
- Product damage — mis-stacked pallets lean, shift, and fall — damaging product and creating safety hazards
- Underutilised height — many warehouses leave top racking levels empty because manual operators can't safely reach them
How Autonomous Stacking Works
Precision Positioning
Self-adaptive fork technology adjusts pallet position in real-time during the lift cycle. Pallets are placed with consistent accuracy regardless of height — the 500th stack of the day is as precise as the first.
Height Maximisation
Our reach trucks stack to 9 metres with full accuracy. This unlocks upper racking levels that many operations leave empty, increasing storage density by 20-40% without building expansion.
Zero Racking Contact
LIDAR-guided positioning ensures the forklift never contacts racking during stacking or retrieval. Racking damage drops to zero, eliminating repair costs and safety inspections.
WMS-Directed Placement
The WMS directs each pallet to its optimal storage location based on product velocity, weight, and picking sequence. No operator judgement required — every pallet goes where the system calculates it should.
Stacking Fleet Recommendations
| Height Range | Model | Capacity at Height |
|---|---|---|
| Up to 3.0m | 1.5T Pallet Stacker | 1,500 kg |
| Up to 4.5m | 3.0T CB Stacker | 3,000 kg |
| Up to 5.5m | 1.4T Reach Truck | 1,400 kg |
| Up to 9.0m | 2.0T Reach Truck | 2,000 kg (at 7m standard) |