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PALLET HANDLING & STACKING

PALLET HANDLING & STACKING
STACK
Precise

Centimetre-accurate pallet pickup and placement across heights up to 5.5 m, with automatic load-detection and rack interfacing.

How It Works

Detect

Detect

Vision + laser scanners locate the pallet, confirm load integrity and verify clear approach paths.

Lift

Lift

Precision forks engage at any height up to 5.5 m, with hydraulic levelling for unstable loads.

Stack

Stack

AGV positions the pallet in the assigned rack slot or stack, double-checking placement before retreat.

Return

Return

Auto-routes to the next task or charging dock, updating the WMS in real time.

PRODUCT RANGE

Our Pallet Handling Range

High-reach stackers and pallet trucks for dense warehouse automation.

APEX 150

APEX 150

PALLET STACKER

Compact pallet stacker AGV with flexible lift configurations up to 4m. Ideal for medium-duty warehouse operations and narrow aisle environments.

Narrow-aisle stacking Mid-bay storage Workstation transfers
Max lift 4,0 m
Max payload 1,500 kg
Explore APEX 150
APEX 250

APEX 250

Pallet Stacker

Heavy-duty pallet stacker designed for high-reach storage operations up to 5.5m, with 2500kg capacity for the most demanding warehouse environments.

High-bay racking Multi-tier racks Heavy pallets
Max lift 5,5 m
Max payload 2,500 kg
Explore APEX 250
DELTA PALLET TRUCK

DELTA PALLET TRUCK

PALLET TRUCK

High-speed pallet transport system capable of handling loads up to 3000 kg, featuring integrated barcode scanning and extended fork options for efficient horizontal material handling.

Horizontal pallet transport Dispatch staging Floor-level moves
Max payload 3,000 kg
Max Speed 2.0 m/s
Explore DELTA
BASE

BASE

Compact Stacker

Most versatile shuttle AGV with optional lifting capability, tri-level load capacity configurations and industry-leading battery life for maximum operational uptime.

Shuttle + lift hybrid Tri-level loads Multi-zone facilities
Payload 1,200 kg
Max Speed 1.6 m/s
Explore BASE

AGV Systems for Pallet Handling Operations

Designed for High-Density Pallet Operations
Pallet lifting & placement High-reach rack storage Vertical pallet movement Dispatch & staging area transfers High-density warehouse operations

These systems are ideal for warehouse environments where lifting precision and storage density are critical.

Our Pallet Handling AGV Range

APEX 150

Compact pallet stacker with flexible lift configurations up to 4m.

Ideal for:
  • Medium-duty warehouse operations.
  • Narrow aisle environments.
  • Flexible storage layouts.

APEX 250

Heavy-duty pallet stacker for high-reach storage operations up to 5.5m.

Ideal for:
  • High-density warehouse storage.
  • Heavy pallet handling (2500 kg).
  • Heavy pallet handling.

DELTA Pallet Truck

High-speed pallet transport with integrated barcode scanning.

Ideal for:
  • Horizontal pallet movement
  • Dispatch and staging transfers
  • 3000 kg load handling

How Pallet Handling AGV Systems Work

Navigation Systems

Laser or guided navigation allows AGVs to move across factory layouts safely while compensating for trailer dynamics.

Fleet Management Software

Controls routing, task allocation and traffic between vehicles for optimised logistics flow.

System Integration

AGVs connect to MES, WMS and ERP systems to receive tasks and coordinate with production schedules.

Continuous Execution

Vehicles move materials across defined routes delivering to production lines on schedule.

Pallet Handling AGV Robots

BATTALION pallet handling AGVs combine industrial sensors, navigation systems and precision lifting technology to automate high-density pallet movement in warehouses.

4.8 m
Lift Height
2500 kg
Max Load Capacity
1.4 m/s
Max Speed

Key Features of Pallet Stacker AGVs

High-Reach Stacking

Lifts pallets up to 5.5m with sub-centimetre placement precision, enabling true high-density rack storage operations.

Heavy-Duty Payloads

Engineered for pallet loads up to 2500 kg with hydraulic levelling for unstable or shifting cargo.

Vision & Laser Detection

Combined vision + laser scanning verifies pallet integrity and rack alignment before every pick or place.

WMS Integration

Connects directly to your WMS, MES and ERP to receive tasks and stream pallet location data in real time.

Industries Using Pallet Stacking AGVs

Warehousing & Logistics
Industrial Manufacturing
Distribution Centres
Cold Chain Storage
High-Density Storage

Benefits of Pallet Stacking Automation

Maximise Storage Density

High-reach stacking unlocks vertical capacity, fitting more pallets into the same footprint.

Eliminate Manual Forklifts

Replace forklift drivers on routine stacking with consistent automated handling.

Improve Placement Accuracy

Sub-centimetre pallet placement reduces rack damage and inventory loss.

Increase Throughput

Continuous pallet flow without operator handoffs accelerates pick, put-away and dispatch cycles.

Improve Floor Safety

Predictable AGV paths and laser safety zones lower the risk of pedestrian incidents.

24/7 Operation Capability

Maintain continuous pallet stacking operations across shifts without operator fatigue.

Navigation Technologies Used

Technical Specifications

Max Payload
2500 kg
Max Lift Height
5.5 m
Max Speed (Loaded)
1.2 m/s
Max Speed (Unloaded)
1.4 m/s
Function
Pallet Lifting & Stacking
Navigation Type
Laser SLAM / Magnetic
Battery Type
Lithium-Ion (24 kWh)
Operating Temperature
-10°C to 45°C
Protection Rating
IP54
Pallet Detection
Vision + Laser Scanner

Frequently Asked Questions About Pallet Stacker AGVs

Pallet stacker AGVs lift, transport and stack pallets between storage racks, production lines and dispatch areas, replacing manual forklifts for routine pallet handling.

The BATTALION APEX 250 lifts pallets up to 5.5 m, with APEX 150 configurations supporting 3 m and 4 m for medium-reach operations.

A stacker (APEX) lifts pallets vertically into racks. A pallet truck (DELTA) transports pallets horizontally at floor level. Many warehouses use both.

Yes. the APEX 150 is engineered specifically for narrow-aisle environments, with compact turning radius and precision laser navigation.

Yes. BATTALION stacker AGVs connect to your WMS via standard protocols to receive put-away/pick tasks and stream real-time pallet location updates.

Laser SLAM for layout-flexible operations and magnetic line guidance for fixed-route deployments, selected per warehouse layout.

Ready to Automate Pallet Stacking in Your Warehouse?

Speak to a specialist about implementing pallet handling and stacking AGV systems tailored to your operation.

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