MDP Serwis selects, installs, and services pallet lines primarily from two manufacturers: IMH Machinery and Stakma (PalletMax and PalletStar series). For pallet sorting and repair lines, we also supply Cekamon machines.
Four types of lines, differing primarily in staffing requirements
Pallet production lines are categorised not so much by output, but by the amount of manual labour involved. This determines the cost, staffing levels, and how well the line handles changes in product range.
Semi-automatic: operator loads, machine nails
In a semi-automatic machine, the operator feeds the components, and the machine positions them and drives the nails. An example from our used machinery range is the two-stage KOMBI-FLEX R-1000 pallet nailing machine: pallet bottoms are produced in one jig, and top deck boards are nailed in the second; it requires two operators, with a stated output of approximately 500 pallets per 8 hours. A semi-automatic machine makes sense where the volume does not yet justify a full line, but you require nailing consistency that a manual nail gun cannot provide.
CNC automatic machine: one machine for many pallet types
Stakma CNC pallet nailing machines from the PalletMax and PalletStar series are automatic pallet machines where the operator places boards and blocks onto a jig, and the machine nails them according to a program. Jig changeover takes 1 to 5 minutes (PalletMax) or 3 to 10 minutes (PalletStar) according to the manufacturer's specifications, and requires one or two operators. The PalletStar features a rotary table with three zones: in the first, the operator places the boards; in the second, the automatic machine nails; and in the third, a robot picks up the finished pallet. This ensures no one waits for the machine, and the machine does not wait for a person.
Robotic line: fewer staff for the same output
In a pallet line, a robot most often transfers components between machines, turns pallets, or stacks them. A comparison of two IMH lines from our range clearly demonstrates what a robot actually changes. IMH SIMPLE X1500 and IMH Kombiline ST X1600 have the same stated output of 4 pallets per minute. The first requires a crew of three to four people, while the second, with a robot transferring top decks and pallet bottoms, requires one to two. The robot did not speed up the line. It reduced the number of personnel.
It's worth stating this directly, as we often hear that a robot “will increase production”. If the nailing machine is the bottleneck, a robot will not change that. However, it will change the number of positions you need to staff per shift, and that is the right reason to consider it.
Line for non-standard and perimeter base pallets
Non-standard pallets are where the industry earns the most, and they are most often produced manually, due to the belief that this cannot be automated. It can be done, provided the same non-standard design recurs regularly. PalletMax nailing machines produce pallets up to 12 metres in length, including perimeter base and non-standard pallets, with a working area ranging from 2400x1700 to 11400x1700 mm. For stringer pallets and perimeter base pallets, IMH offers separate configurations, such as the IMH BBMSIMPLE X1500 with a perimeter base pallet machine and a flip-flop turner that rotates the pallet by 180 degrees.
A single prototype is still better nailed manually. A line for non-standard pallets becomes cost-effective when the same design is required weekly.
Line output is determined by the slowest machine, not the fastest
A pallet production line operates at the pace of its slowest component. Therefore, we calculate output based on the pallet you produce most frequently, not the figure from a brochure.
A simple example from our machine specifications. A block pallet has three legs. A leg machine in the 12 legs per minute version therefore provides material for 4 pallets per minute. The SSM-P 1503S-V assembly machine connects 4 pallets per minute according to its specifications, when the pallet is up to 1400 mm long and the legs have three blocks each, but only 3.5 pallets per minute for lengths up to 2500 mm and five blocks. The same line, a different pallet, results in one-eighth fewer units per shift.
When selecting a line, we therefore check:
- Order structure. What percentage are EPAL, what percentage are stringer pallets, and what percentage are non-standard pallets. A line for stringer pallets, such as the IMH Stringer X1500, is designed for facilities where this type constitutes the vast majority of orders. For a mixed product range, a CNC automatic machine with quick jig changeover will be more suitable.
- Volume per shift. Some configurations are designed for a specific scale. The IMH 2STEP X1000 connects the base to the deck without a separate assembly machine and is designed for producing up to 1,000-1,200 pallets per shift.
- Changeover frequency. According to IMH line specifications, changeover takes 15 to 30 minutes, while on PalletMax and PalletStar lines, it takes 5 to 15 minutes. With several pattern changes per day, this difference becomes more significant than output per minute.
- Available staff. A line requiring four people per shift will not help a plant that cannot staff two.
- Hall. Height, space for feeders and stack outfeed. For a stacker and turner, the recommended hall height is 3700 mm, and for PalletMax with an ABB robot, it is 4500 mm.
Components of a pallet production line
A complete block pallet nailing line usually consists of five stages. Most of these machines can also be purchased separately and added to existing production.
- Block cutting. The OPK 5800V block saw measures the squared timber and cuts the maximum number of blocks from it, 55 per minute for 75 mm blocks. With a cutting tolerance setting of plus or minus 2 mm, a 2948 mm squared timber yields 30 blocks instead of 29.
- Nailing of pallet bottoms and top decks, or the entire pallet. In IMH lines, the leg machine and the deck machine operate separately. In CNC automatic machines, the entire pallet is nailed by one machine: Stakma pallet nailing machines or, in the semi-automatic version, the KOMBI-FLEX R-1000.
- Assembly. The assembly machine connects finished top decks with pallet bottoms, with or without so-called wings.
- Turning and transfer. The ROV 2160 pallet turner transfers pallets from the machine to the stacker and can rotate them by 180 degrees, allowing pallets to be stacked “one into another”.
- Processing and stacking. The AT finishing line brands marks, trims corners, and mills the bottom boards for forklift entry. The STP 1502 stacker stacks top decks and 4-way pallets 'one on top of the other' or nested, counts pallets, and measures stack height.
If you handle sorting and repair of used pallets, there is a separate set of machines described on the Pallet sorting and repair page.
Example lines from our range
Below are configurations detailed module by module. Figures are taken from the line specifications. All lines come with a 12-month warranty.
| Line | Purpose | Output | Operators | Changeover |
|---|---|---|---|---|
| PM-STD X400 | PalletMax + ABB robot for stacking | 400 pallets / 8 h | 1-2 people | 5-15 min |
| PM-ATCR X400 | PalletMax + ABB robot + 3-in-1 finishing, non-standard pallets | 400 pallets / 8 h | 1-2 people | 5-15 min |
| PS-CCU X400 | PalletStar with rotary table and corner cutting saws | 400 pallets / 8 h | 1-2 people | 5-15 min |
| IMH 2STEP X1000 | Pallet bottoms + top decks with assembly, without an assembly machine | 3 pallets / min | 3-4 people | 15-30 min |
| IMH Stringer X1500 | Stringer pallets | 4 pallets / min | 1 person | 15-30 min |
| IMH Kombiline ST X1600 | Full block pallet line with transfer robot | 4 pallets / min | 1-2 people | 15-30 min |
| IMH Kombiline GP X1600+ | full line with robots and finishing | 4-7 pallets / min | 1-2 people | 15-30 min |
All configurations, including sorting and repair lines, can be found under the Production lines tab.
How much does a pallet line cost and how to finance it
The price of a pallet production line depends on the number of modules and the degree of automation, which is why we do not publish a price list. A semi-automatic machine and a complete robotic line are investments that differ by an order of magnitude. We prepare a quotation after a discussion, once we understand what types of pallets, in what quantities, and with what staffing levels you intend to produce.
Before you compare the price of a line with anything else, calculate the true cost of a manually produced pallet. Most facilities only account for the pallet assembler, overlooking the forklift driver, block cutting, corner trimming, and marking. In one example from our article on manual production errors, a facility produced 800 to 1000 pallets daily manually with eight to ten people, and after switching to a line, produced 1500 pallets daily with three to four people. How to calculate this for your own operations, step by step, is shown in the article What are the real costs of manual pallet production.
The line can be financed through leasing or grants. We have described current programmes in the post EU grants and loans 2026. We deal with machinery, not finance, so it is worth calculating the specific financing structure with an advisor or a leasing company.
Installation, commissioning and service
A pallet production line is more than just delivery. Our service technicians assemble and test machines before and after delivery, and service is free during the warranty period. For Stakma automatic machines, we provide operator training, and the manufacturer offers online support. After the warranty, we handle service, repairs, refurbishment, and relocation of the lines. Details on the Service page.
Frequently asked questions about pallet production lines
Which pallet production line to start with?
For a facility that currently nails pallets manually and produces several pallet types, the most common solution is a CNC automatic machine with quick jig changeover, for example from the PalletMax or PalletStar series, operated by one or two people. A full IMH line with separate leg, deck, and assembly machines makes sense for large, repetitive volumes.
How many pallets can a pallet line produce per day?
According to our line specifications, from 400 pallets per 8 hours (PalletMax and PalletStar automatic machines with a robot) to 4-7 pallets per minute (full IMH Kombiline lines). The actual output depends on the pallet type: the same assembly machine produces 4 pallets per minute for short pallets with three blocks and 3.5 for long ones with five blocks.
How many people are needed to operate a pallet production line?
From one person (IMH Stringer X1500, stringer pallets) to three or four (lines without transfer robots). A robot usually does not increase output, but rather reduces the number of people per shift.
Is it possible to automate the production of non-standard pallets?
Yes, if the same design recurs regularly. PalletMax nailing machines produce pallets up to 12 metres in length, including perimeter base and non-standard pallets, with jig changeover in a few minutes. Individual units and prototypes are still quicker to nail manually.
Can I expand the line in stages?
Yes. Most IMH machines, such as the block saw, leg machine, finishing line, and stacker, can operate independently or as part of a line, so you can start, for example, with a leg machine or block saw and add further modules. Stakma automatic machines can be expanded with an ABB robot for stacking.
Do you have used pallet lines?
Yes, current listings for used machinery and lines can be found on the Used machinery page. We also mediate the sale of machines you wish to replace.
Please tell us what types of pallets you produce, how many units per shift, and how many people you have involved in production. We will advise which configuration makes sense for you and which would be over-engineered for your needs.
