Grippers for the recycling economy
Zimmer Group supports BHV-Automation in fully automated pallet recycling
Euro pallets are a central and, at the same time, safety-critical component in intralogistics. In the worst-case scenario, wobbly or damaged pallets can lead to property damage or personal injury. At the same time, pallets represent a significant cost factor: depending on the design and market conditions, the cost of new pallets typically ranges from 5 to 25 euros per unit.
In the woodworking industry, there is therefore a growing need for solutions that not only inspect used pallets but also automatically convert them into reusable components. In this context, automation not only means increased efficiency but is also the logical next step toward an industrial circular economy.
The Task: Fully Automated Disassembly
For special-purpose machine construction, BHV-Automation has developed a robot-assisted pallet sawing system that independently identifies, analyzes, and precisely disassembles used pallets without requiring manual adjustments. The development therefore focused on industrial robotics for safe handling, a specially developed sawing unit, and intelligent software/AI that dynamically controls the process.
The software analyzes dimensions, height, and deck orientation, automatically selects the appropriate sawing program (2–5 layers), and adapts the sequence—even with random pallet sequences and varying conditions. In the future, I-Pal_Inspekt, a non-contact pallet integrity inspection system, will be implemented: Two scanning towers equipped with 3D cameras inspect the top, sides, bottom, and interior surfaces. Operation is controlled via a touch panel in the control cabinet.
From the outset, clear requirements were therefore set for the overall solution: The process was to run entirely without operator intervention, including automatic program selection and continuous process monitoring. At the same time, consistent, reproducible processing quality was required to standardize the results regardless of the operator, shift, or condition of the pallets. Equally crucial were high process reliability and the ability to operate the system either as a standalone unit or to integrate it into existing sorting and repair lines. Since different formats must be processed in practice, the system had to be able to reliably handle pallets ranging from 800 to 1,400 mm. Finally, it was essential to ensure robust handling that functions stably and reliably—even under heavy contamination and high mechanical stress—in the real-world conditions of daily recycling operations.
High Gripping Force with the GPP5000 Series
In this application, the gripper plays a central role: It reliably grips the pallet during the process, positions it securely for processing, and thus enables the controlled disassembly of damaged pallets to recover reusable components.
BHV-Automation relies on the premium GPP5000 gripper series from the Zimmer Group for this purpose. The gripper is ideally suited for the harsh conditions of pallet recycling. Contamination, dust, splashing water, and mechanical load spikes are not exceptions but part of normal operation. It is precisely here that it is determined in practice whether robot cells operate stably over the long term or whether downtime and rework compromise cost-effectiveness.
For BHV Automation, three characteristics were of particular importance: The combination of robust mechanics and process-reliable gripping is especially crucial in recycling applications: The load on the gripper is high, the environment is harsh—and yet the grip must function with repeatable accuracy and reliability to maintain the stability of the automated sawing process.
- High performance thanks to the patented steel-on-steel guide
- Protection against dust and splashing water included as standard—a key factor in highly contaminated applications
- High gripping force during closure for safe handling even with varying pallet conditions
The Zimmer Group is far more than just a component supplier; it also served as a partner in designing the necessary components for the process. Throughout the project, expert consultation, quick response times, short lead times, and a fair price-performance ratio are crucial for turning a good idea into a production-ready, scalable solution.
Reproducible quality, high safety, and measurable productivity
The system from BHV-Automation demonstrates how industrial 3D machine vision technology, robotics, and robust gripping technology can be combined into a comprehensive, industry-ready solution. This offers clear advantages for operators:
For operators:
- no more manual handling required
- automated parameterization
- safe handling at a safe distance from saw blades
- automatic program selection/process monitoring
- 80% reduction in staffing requirements
Benefits for companies:
- reduced staffing requirements
- consistent quality—regardless of the operator
- Modularly expandable and compatible with production lines
- High process reliability and scalability
The cycle time also underscores the system’s industrial capabilities: approximately five seconds per saw cut. This transforms pallet recycling into a reproducible, predictable process with maximum value creation through precise disassembly and seamless return of reusable components.
Conclusion
For pallet recycling to evolve from a workshop-based approach to an industrial circular economy, it requires not only state-of-the-art measurement technology and robotics but, above all, reliable gripping. With the GPP5000 series, the Zimmer Group provides the robust foundation to ensure that automated disassembly functions reliably even in the presence of contamination and during peak loads.
