Service kit: Pallet layer control

In palletising applications, layers of product are automatically stacked on a pallet. It is essential to verify that layers are formed correctly before they are palletised. Any shape irregularities or wrongly prepared pallet layer patterns can cause big problems resulting in downtime and product damage. Our new pallet layer vision control prevents this.

Upgrade your palletiser with the 3D Vision control


Our solution:

Alvey introduces a 3D Sensor technology, which performs the thorough check of the product packaging and layer formation quality.

It ensures the detection of:

  • Cases with open flaps or irregular shape
  • Cases with incorrect dimensions within the layer
  • Missing cases in the layer
  • Too many cases in the layer
  • Wrongly orientated cases within the layer

This means following benefits:

  • No productions losses caused by machine downtime during cleaning or evacuation
  • No cleaning costs in case of collapsed pallets (imagine yoghurt)
  • No product losses
  • Avoids possible machine damage
  • No costs of re-stacking products on mixed up pallets (a mistake can last over more pallets, before it is noticed).
  • Saved costs of replacing, administration, bad traceability, etc. in case some products go to a wrong customer.

Functional description: 

  • The 3D sensor (pictured) is mounted at about 2,25 m above the layer formation zone.
  • The sensor is triggered by the palletiser PLC when the layer is ready to be deposited on top of the previous layer. 
  • The sensor sends dimensional information for the defined regions of interest to the palletiser PLC. 
  • The PLC compares this data with the pallet layer reference data, and then decides whether the prepared layer complies.
  • In case of rejection, the palletiser stops, and the faulty region is visualized on the touch panel. (see figure underneath).
  • Reference data for new layer patterns can be easily created additionally. 


  • Free height of 2,5 m above the machine’s layer formation zone.
  • Siemens PLC with integrated Ethernet port and operator display.

Note 1: The comparison and visualization program code needs to be integrated in the existing palletising PLC application.  

Note 2: If the existing palletiser PLC  does not fulfill the requirements to integrate the 3D sensor, Alvey can also deliver a dedicated PLC / operator interface for the 3D application, that receives pattern information from the palletiser PLC. The 3D sensor PLC will return the comparison result via basic I/O signals to the palletiser PLC.

Picture: Screenshot of comparison data on the touch panel

Reference data can be taught and manually modified.


Every application is different and needs to be handled as a project. The project typically comprises following steps:

  • Feasibility study
  • Detailed design 
  • Purchase and production 
  • Installation
  • Commissioning

Contact our service team for details and price offers.