Box stacker/destacker

Automatic tray stacker/de-stacker is a solution for the supply and accumulation of totes, designed to stabilize material flow within the warehouse system. Wherever the timely availability of containers depends on manual handling, delays, uneven workloads, and productivity losses are inevitable.

Key challenges addressed by a box stacker/de-stacker:

• box shortages at workstations – ensured by continuous accumulation and automated delivery of empty containers to operational zones;
• workforce optimization – the automation of stacking containers reduces manual workload and allows operators to concentrate on higher-value tasks;
• uneven material flow – balances container supply between areas operating at different speeds;
• slow return cycle of returnable boxes – accelerates container recirculation within the picking process, reducing the need for additional inventory.

The KAPELOU solution is designed for stacking containers sized 600×400×220 mm and 600×400×300 mm.

Stackers and destackers deliver proven value across various market segments: e-commerce & retail (continuous, reliable supply of totes and boxes during peak operational hours), pharmaceutical distribution (precise container feeding and compact accumulation of plastic bins to meet strict process requirements), closed-loop systems (valuable floor space, optimize empty box storage, and significantly cut container handling costs).

Automatic box stackers/destackers eliminate one of the most overlooked sources of inefficiency in warehouse operations – manual handling of containers and trays.

Key benefits:

• High throughput – supports intensive material flows without compromising operational pace.
• Stable, continuous tote flow – automated singulation and supply of containers and trays eliminates delays and ensures consistent performance of picking and packing areas, especially during peak periods.
• Reduced reliance on manual labor – automation of repetitive tasks lowers labor costs and minimizes the impact of human error.
• Improved working conditions – the system takes over routine operations, enhancing safety and overall employee comfort.
• Gentle handling of containers – precise stacking of trays reduces wear and extends the lifecycle of returnable packaging.
• Compatibility with standard tray sizes – enables seamless integration into existing lines without the need for modifications.
• Seamless integration – full compatibility with conveyor systems and WMS/WCS ensures synchronized operation across the entire intralogistics system.
• Long-term reliability – engineered for stable performance under continuous high-load conditions.

In pharmaceutical distribution centers, even short delays in tote supply can negatively impact order accuracy and fulfillment speed. In one project for a German pharmaceutical distributor, the KAPELOU automated destacker enabled continuous conveyor-fed tote supply, eliminating dependency on manual handling processes.

Implementation results of the destacking technology integration:

• stabilized material flow – automated destacking and conveyor delivery of up to 500 boxes/hour ensures consistent replenishment of picking and packing areas;
• operational continuity under peak loads – constant tote conveying eliminates downtime during high order volumes;
• reduced reliance on manual labor;
• integrated machine control with conveyors and WMS/WCS enables synchronized workflows across all zones.

In pharmaceutical logistics, destacking technology brings predictability to order fulfillment. An advanced KAPELOU tote destacker machine ensures automatic disruption-free conveying while improving intralogistics speed, precision, and efficiency. The total cost of deploying stacking and destacking technology depends directly on the integration complexity within the facility’s existing intralogistics infrastructure.

Submit a request using the form below to order a stacker or destacker for crates, including a preliminary assessment of line capacity. Together we implement automatic stacking/destacking technology and eliminate bottlenecks in your tote flow to build a more efficient intralogistics.