If your operation builds mixed-SKU pallets taller than standard automation handles — with varied case dimensions and real throughput demands — the Tall Pallet Station was built for you.
Max pallet height
Unique SKUs per pallet
Cases per hour
Worker per cell
Built by hand, one face at a time — this is what a 108″ mixed-SKU pallet usually looks like before it ships. Or before it falls.
Most warehouse automation is built for the predictable case — single-SKU pallets, consistent case dimensions, standard heights. When your outbound profile means mixed SKUs, pallets pushing 90 or 108 inches, and a worker who today walks miles of floor to build each one — the standard vendors either can’t quote it or walk away.
The Tall Pallet Station was designed specifically for this order profile. Not as a workaround. As a purpose-built robotic cell — with PES orchestrating every pallet, every pick, every robot move from inbound delivery to finished pallet dispatch.
We deploy it for operations with 25+ unique SKUs per pallet. We deploy it with 20 qty per line and we deploy it with fewer than 3. If tall mixed-SKU pallets are slowing your operation down, the profile almost certainly fits.
The Tall Pallet Station is one large robotic cell — not a collection of parts from different vendors. Prime MobilePallet robots continuously replenish source pallets at the base while one worker on the elevated platform builds multiple outbound pallets simultaneously. Everything is orchestrated by PES.
This is the entire operator interface, live on the floor. PES directs every pick as a single unmistakable action — pick from this donor, build to this pallet — so even with 25+ SKUs there’s no confusion about what goes where. Product comes to the worker at the ideal height; the screen tells them the rest. A new hire runs this station in minutes.
Each numbered station around the platform is an independent pallet build. While the worker places cases on station 01, PES is routing the next source pallet to station 08. The result is dramatically higher throughput per labor hour than any conventional pick-and-pack approach for these order profiles.
When a pallet is complete, a Prime MobilePallet robot picks it up and carries it — all 108 inches of it — to staging, stretch wrap, or dispatch. No forklift intervention. No manual handling. The full flow from inbound inventory to outbound pallet is managed end-to-end by PES.
See every stage of the TPS workflow — from inbound pallet delivery through finished pallet departure. TPS is currently being developed, deployed and optimized — demo days planned for late summer to early fall.
Most automation vendors sell you hardware and leave the integration to someone else. The TPS runs on PrimeOS — Prime’s warehouse operating system — with PES, the Prime Execution System, as the engine orchestrating the cell in real time. It manages the flow of every pallet, every pick, every robot move across the entire operation. When your needs change, you change the workflow — not the hardware.
VP Operations, Consumer Goods Distributor
The Tall Pallet Station is currently being developed, deployed and optimized. We’re offering private virtual walkthroughs for qualified prospects now, with demo days planned for late summer to early fall.
A 20-minute Teams call where we walk through the animation, share footage from active deployment, and assess your order profile fit.
Share your SKU count, qty per line, and pallet height targets. We’ll tell you quickly whether TPS is the right fit for your operation.
We’re planning our first TPS demo days for late summer to early fall. Register your interest now to be among the first invited.
