Building mixed-SKU pallets up to 108 inches tall with sub-3 quantity per line and 25+ unique SKUs of varying case dimensions on a single pallet has defied automation — until now. The Prime Tall Pallet Station is a complete robotic cell designed for exactly this problem. Our first system is deploying in Pennsylvania right now.
Max finished pallet height
Unique SKUs — mixed dimensions — on one pallet
Qty per line order profiles
Worker. Multiple pallets. Simultaneously.
Most warehouse automation vendors are optimized for the easy case — single-SKU pallets, high quantities per line, standard heights. When your operation involves low-quantity, high-SKU order profiles building pallets that tower above conventional limits, most vendors walk away.
They walk away because it requires more than a robot. It requires a complete rethinking of the pallet-building workflow — how product arrives, how the worker interacts with it, how multiple pallets build in parallel, and how the finished pallet leaves. It requires software that orchestrates every step.
That’s exactly the kind of problem Prime was built for.
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.
The elevated platform means the worker never bends, never reaches, never walks the warehouse floor chasing product. Source pallets are raised to the ideal working height. PES directs every pick with scan confirmation, so even with 25+ SKUs per pallet there’s no confusion about what goes where.
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. Our first system is currently deploying in Pennsylvania, with full customer operation expected by end of May.
Most automation vendors sell you hardware and leave the integration to someone else. The TPS only works the way it does because every component was designed to work together — the robots, the station, and the software that orchestrates it all.
PES — Prime’s workflow-based Warehouse Execution System — is what makes the TPS more than a machine. It manages the flow of every pallet, every pick, every robot move across the entire operation. When your needs change, you change the workflow in PES. You don’t rip out hardware.
Workflow-based Warehouse Execution System
Our first Tall Pallet Station is going live in Pennsylvania right now — full customer operation expected by end of May. We’re offering private virtual walkthroughs for qualified prospects while the system ramps up, with site visits opening in July.
A 20-minute Teams call where we walk through the animation, share live footage from the Pennsylvania deployment floor, 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.
See a fully operational TPS in person at our Pennsylvania customer site. Register your interest now to be first in line.
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