Pallet Changers Buyers Guide
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Buyer Guide
Pallet Changer Selection Guide
Compare pallet changer designs side by side: cycle profile, load capacity, configurations, and practical pros/cons so you can choose the right tipper for your roll handling, product orientation and production/shipping workflow.
Pallet Changer/Load Transfer Comparison
A quick side-by-side view of design tradeoffs: applicatiom, strength, handling, and construction method.
| Model/Type | Typical Capacity | Loading/Unloading | Cycle/Profile | Key features | Key Diffentiators & Best Fit |
|---|---|---|---|---|---|
| RM-1150A – Load Transfer System (LTS) | Heavy duty (commonly 2,000–4,000 lb+, application-engineered) | Forklift, conveyor, AGV/AMR | High-throughput / continuous-ready | Stripper plate transfer minimizes product disturbance; engineered for automation and captive pallet programs | Engineered for uniform boxed finished product; pusher advances product onto a stripper plate that retracts to gently lower the load onto the pallet |
| PC-80 – Pallet Changer | Medium to heavy (commonly 1,500–3,000 lb) | Ground-level load & unload with pallet jack | Moderate, repeatable cycles | Traditional clamp-style pallet change; accommodates varied pallet sizes; simple operator interaction | Ideal where forklifts are restricted and flexibility with pallet types is required |
| DV-PE96 – Deep V Pallet Changer | Medium to heavy (commonly 1,500–3,000 lb) | Ground-level load & unload with pallet jack | Faster than standard pallet changers | Deep-V load support improves stability; staged pallet exchange reduces idle time | Best for higher-cycle operations needing stability and throughput without automation |
| PSR-90 – Pallet / Spacer Retrieval | Medium to heavy (commonly 1,500–3,000 lb) | Ground-level load & unload with pallet jack | High-speed option available | Roller-bed assist simplifies pallet exchange; designed for efficient pallet or spacer recovery; minimal operator effort | Lower-cost alternative to traditional pallet changers; boxed product only; ideal where speed, simplicity, and cost control are priorities |
| PWL - Pallet Wall | Medium to heavy (commonly 1,500–3,000 lb) | Forklift with load rest | Floor fixed, push onto adjacent pallet | Space saving device for extremely light loads. | Lowest cost manual pallet transfer, eliminates hand stacking/restacking boxes. |
Pros
- LTS Load Transfer System – The pusher and stripper-plate transfer method gently lowers the product onto the pallet, minimizing product disturbance while enabling faster cycle rates than traditional pallet changers. Its design integrates well with conveyors, AGVs, and automated pallet dispensers.
- PC Pallet Changer – The PC-80 handles a broad range of pallet sizes and load profiles, including boxed, bagged, and irregular loads when properly contained. Ground-level operation improves ergonomics and safety while simplifying installation in space-constrained facilities. Its proven mechanical design offers predictable performance, lower integration complexity than automated systems, and strong long-term reliability.
- DV Deep V Changer – The DV-PE96 Deep V Pallet Changer enhances load stability during pallet exchange by cradling the product in a Deep V configuration, reducing the likelihood of load shift compared to flat clamp designs. Ground-level pallet-jack loading and unloading improves ergonomics, limits forklift traffic, and supports safer operation in food, beverage, and CPG environments.
- PSR Pallet Retriever – The PSR-90 provides a fast, economical solution for pallet or spacer removal and replacement using a roller-bed assist that minimizes operator effort and cycle time. Ground-level pallet-jack loading and unloading improves ergonomics and reduces forklift traffic, making it well suited for distribution environments. As a lower-cost alternative to traditional pallet changers, the PSR-90 delivers high-speed performance for stable, boxed unit loads where simplicity and throughput are priorities.
- PWL Pallet Wall – A simple, low-cost solution for transferring extremely light palletized boxed loads from one pallet to another. With no moving parts, controls, or power requirements, it offers high reliability and minimal maintenance. The fixed wall design reduces mechanical complexity while allowing operators to complete pallet transfers using existing forklifts. This approach works well in low-throughput applications where capital budgets are limited and automation is not justified.This approach works well in low-throughput applications where capital budgets are limited and automation is not justified.
Watchouts / Cons
- LTS Load Transfer Ssytem - The LTS does not perform well with pallets that have a top-deck lip, as this can interfere with clean product transfer. It is not recommended for bagged or heavy, dense products that may mold into the spacing between deck boards, which can cause product hang-up or damage during transfer. Additionally, pallets with splinters, broken boards, or protruding nails can damage product and compromise transfer reliability, making pallet condition and design critical to success.
- PC Pallet Changer - Cycle times are slower than load-transfer systems and may not be ideal for high-volume or continuous-flow operations. Load stability is critical—unstable, poorly wrapped, or overhanging loads can limit clamp effectiveness and require additional containment. Throughput is operator-dependent, and facilities with frequent pallet changes or future automation plans may outgrow a traditional pallet changer over time.
- DV Deep V Changer – Proper load geometry is critical to successful operation; irregular footprints, excessive overhang, or poorly wrapped loads can compromise stability and change reliability. The DV-PE96 is not suitable for bagged products, super sacks, or drums, as these load types do not provide the rigid, uniform structure required for Deep V support.
- PSR Pallet Retriever – The PSR-90 is limited to boxed product only and is not suitable for bagged goods, irregular loads, super sacks, or drums. Manual handling of the pallet is required to remove the empty pallet and tip in the replacement pallet, which should be considered when evaluating labor requirements and ergonomic impact. Load stability and consistent footprints remain critical to ensure reliable operation and safe pallet exchange.
- PWL Pallet Wall – Is limited to extremely light, stable, and well-wrapped boxed loads and is not suitable for bags, drums, super sacks, or irregular products. The process relies heavily on operator technique, as the operator must place the transfer pallet on the floor and drive the load against the wall opening to complete the transfer. Poor load geometry, overhang, or weak pallet construction can result in product shift or collapse. Because forklifts are actively involved in the transfer, there is increased risk of product damage and reduced consistency compared to automated pallet changing solutions.
Best Use by Pallet Changer Type
Quick recommendations based on what matters most: budget, capacity, durability, or asset life.
Load Transfer System (LTS) Model: RM-1150A
High-volume, uniform boxed finished products; frequent pallet changes; automated or future-automation environments; captive pallet programs.
Traditional Pallet ChangerModel: PC-80
Mixed SKUs and pallet types; moderate cycle demands; ground-level operation; applications prioritizing flexibility and simplicity.
Deep V Pallet ChangerModel: DV-PE96
Boxed, rigid loads with consistent footprints; higher cycle rates than standard changers; improved load stability without full system integration.
Pallet / Spacer Retrieval SystemModel: PSR-90
Boxed product only; high-speed, lower-cost pallet or spacer recovery; freezer and cold-storage operations where manual pallet replacement is acceptable.
Pallet WallModel: PWL-727550.5
A fixed, floor-mounted pallet wall is best suited for extremely light, stable unit loads where the empty pallet remains on the floor and a forklift pushes the load against the wall cutout to transfer product onto a new pallet in low-throughput, manual pallet-changing applications.
Expert Tips for Selecting Pallet Changers & Load Transfer Systems
Safety
Begin by assessing the current state of the operation and the risks you are trying to eliminate, such as manual pallet handling, unstable load tipping, or excessive forklift traffic. Involve EHS early to ensure the equipment provides positive load control, proper guarding, and predictable operator interaction. The safest solution removes variability from the process and minimizes reliance on operator judgment during the pallet exchange.
Ergonomics
Ground-level loading and unloading can significantly reduce physical strain, but it is critical to understand where manual handling remains in the process. Evaluate push forces, pallet tipping, repetitive motions, and reach distances—particularly for systems that require manual pallet removal or replacement. In many cases, a higher upfront investment is justified if it eliminates high-risk ergonomic exposures over thousands of cycles.
Return on Investment (ROI)
Look beyond cycle time and consider the full economic impact, including labor savings, reduced forklift traffic, injury avoidance, improved throughput consistency, and reduced pallet or product damage. Lower-cost systems may deliver quick payback in simple, boxed applications, while engineered solutions often generate stronger long-term ROI in automated or captive pallet programs. Total cost of ownership should include maintenance, training, downtime risk, and service support.
Compatibility
Confirm compatibility with your product, pallet design, and unit load geometry before selecting a system. Boxed versus bagged product, pallet deck configuration, load overhang, and pallet condition directly affect reliability and performance. A consultative partner should validate these variables during discovery rather than assuming a standard solution will work.
Pallet Types & Programs
Understand how different pallet programs will impact the system, including captive pallets for inbound or internal use, rental pallets, and export pallets required for specific customers. Variations in pallet height, top-deck design, weight, stiffness, and overall quality can significantly influence load stability, transfer performance, and equipment wear. Aligning the pallet changer to the pallets you use today—and those you may adopt in the future—is critical to long-term success.
Future Proofing
Consider how the equipment will adapt as volumes grow or processes evolve. Evaluate the ability to integrate with conveyors, AGVs, pallet washers, or captive pallet and sanitation programs over time. Selecting a solution designed with flexibility and scalability in mind reduces the risk of obsolescence and protects the investment throughout the equipment’s lifecycle.