Smart Pallet Handling Conveyor Drives Increased Distribution Throughput

Challenge: Integrating Existing Wrappers into a Fully Automated Pallet Line

When a new high-volume distribution center in coastal Georgia was under construction, the operations team wanted a fully automated pallet handling system that could support heavy production volume and ensure dependable performance from the start. The company planned to distribute thousands of palletized loads each week and needed a system designed for long-term growth.

A key part of the challenge involved integrating existing Wulftec stretch-wrapping machines into the new system design. The layout had to align perfectly with the pre-installed wrappers to maintain smooth product flow and consistent throughput. Because the facility was new, the engineering team also had to design a system that balanced efficiency, operator safety, and space utilization while leaving flexibility for future automation or line expansion.

The system needed to handle a wide range of pallet sizes and weights, accommodate accumulation during peak production, and ensure continuous movement between wrapping and outbound staging. Reducing forklift interaction was also a priority for safety and to prevent bottlenecks around the packaging area.

Solution: Engineered Automation with Alba Conveyors and Smart Controls

AEC was selected to design, engineer, and install the new automated system. Brian Hester, Engineer and Material Handling Specialist, led the project from initial concept through installation and commissioning, collaborating closely with our client’s team to ensure every detail met operational expectations.

The finished design features Alba chain driven live roller (CDLR) conveyors configured to move pallet loads from production through two existing automatic stretch wrappers. The conveyors provide heavy-duty performance capable of handling full pallet loads with minimal maintenance. Chain transfers positioned at strategic points along the line allow pallets to move smoothly between parallel conveyor runs, directing traffic toward the available wrapping station and balancing flow between lanes.

Each conveyor section includes photo-eye sensors and accumulation zones that maintain proper spacing between pallets and automatically stop or release loads as needed. This precise control keeps operations running smoothly even when one wrapping station is temporarily idle for film change or maintenance.

Operators can view system performance, start or stop individual zones, and adjust speed or sequencing directly from the control interface. Every design choice emphasized reliability, ease of maintenance, and uptime, which reflect AEC’s long-standing experience in integrated conveyor systems.

Because the project was completed during new construction, AEC was able to optimize the conveyor path for space efficiency and future scalability. The layout provides wide, clear aisles for forklift access and personnel movement while maintaining tight integration between the production, wrapping, and shipping areas. The Alba conveyors were chosen for their rugged construction, high torque drive systems, and long service life, making them ideal for continuous-duty distribution environments.

Result: 30% Higher Throughput, Fewer Forklifts, Built for Growth

The new automated pallet handling system has provided a major boost in performance since the facility’s first day of operation. By integrating Alba CDLR conveyors, chain transfers, and the existing stretch wrappers, pallet movement will flow smoothly from production through shipping with minimal manual handling.

The system is designed to achieve throughput rates 25–30% higher than standard manual handling operations, maximize safety due to reduced forklift traffic, and help operators maintain steady flow across both wrapping stations.

Photo-eye sensors and accumulation zones ensure precise pallet spacing and controlled movement, preventing backups and keeping both wrappers fully utilized. The result will be a steady, efficient flow that sustains productivity even during peak production hours. Maintenance is simplified with accessible components and modular conveyor sections which helps to reduce potential downtime and simplify adjustments when needed.

The overall system design has given the facility flexibility to adapt to future growth. Additional conveyor runs, palletizers, or overhead transport can be incorporated easily, and the durable Alba components ensure long-term reliability with minimal upkeep. The operation now benefits from improved safety, reduced handling time, and consistently higher throughput.