Use-Case – SMITH Heavy-duty Electric Stacker

The Challenge

A metal fabrication facility near Graz processes about 120 finished pallets per day containing heavy steel parts. Pallets need to be lifted as high as 4.5 m into tall racking systems located in very narrow aisles.

The plant previously used a combination of manual pallet trucks and a semi-electric stacker. Heavy pallets were often moved in two stages: first to a buffer area, then lifted by the semi-electric stacker. This double handling took extra time, put strain on operators, and resulted in 8 damaged pallets per month due to unstable lifting and limited visibility.

Management was looking for a compact, robust electric stacker that could run continuously for 5–6 hours, lift up to 4.5 m in a single operation, and safely handle 2-ton loads in confined spaces.

Manual Process

Before automation, one worker using a manual pallet truck and a semi-electric stacker managed all finished goods. Maneuvering and positioning in the tight aisles was slow, and each heavy pallet required two separate handling steps.

Before Automation:

• Daily throughput: 120 pallets per day
• Cycle time per pallet: 4.5 minutes (manual move to buffer 2.5 min + semi-electric lift/store 2.0 min)
• Total daily time: 120 × 4.5 = 540 minutes (9.0 hours per day)
• Labor cost: 9.0 hours × €25/hour = €225 per day
• Rework/issues: 8 damaged pallets per month (≈ 0.36 pallets per day, average rework and material cost €70 per damaged pallet → 0.36 × €70 ≈ €25 per day)

The semi-electric stacker also required significant physical effort to pump and position heavy loads, leading to operator fatigue. Workers often slowed down for safety, which further reduced throughput during busy periods.

Automated Solution

The facility installed a SMITH Heavy-duty Electric Stacker (2,000 kg, 4.5 m lift) to replace both the manual pallet truck and the semi-electric stacker for finished goods. Its side-drive layout and tight turning radius enabled direct access to high racking in narrow aisles, eliminating the need for a buffer area.

After Installing SMITH Heavy-duty Electric Stacker:

• The machine is run at 60% of its maximum capacity for consistent performance
• New cycle time: 2.7 minutes per pallet (single-step pickup, transport, and lift to 4.5 m)
• Total daily time: 120 × 2.7 = 324 minutes (5.4 hours per day)
• Labor cost: 5.4 hours × €25/hour = €135 per day
• Quality improvement: damaged pallets reduced from 8 to 2 per month (0.09 per day × €70 ≈ €6 per day in damage costs)

The integrated control handle, turtle speed mode, and precise MOSFETS drive allow for accurate positioning at height. One operator can now easily handle the workload with less effort and greater consistency, even during full 5–6 hour continuous shifts.

ROI Calculation

Investment:
Machine price: €5,499 (EXW, price does not include VAT)

Daily savings (labor):
Before: €225 per day
After: €135 per day
Labor savings: €225 − €135 = €90 per day

Daily savings (damage reduction):
Before damage cost: €25 per day
After damage cost: €6 per day
Damage savings: €25 − €6 = €19 per day

Total daily savings:
€90 + €19 = €109 per day

Monthly savings (22 working days):
€109 per day × 22 days = €2,398 per month

Payback period:
Payback = €5,499 ÷ €109 per day ≈ 50 days
50 days ÷ 22 working days per month ≈ 2.3 months
Rounded: payback in just over 2 months

Conclusion

By combining two material handling steps into a single process using the SMITH Heavy-duty Electric Stacker, the metal fabrication facility was able to decrease pallet handling time by 3.6 hours per day and reduce pallet damage by 75%. The purchase price of €5,499 is recouped in just over two months, and operators experience a safer, less physically demanding work environment.

“With the SMITH stacker, we reduced our daily pallet handling from 9 hours to 5.4 hours and lowered monthly pallet damage from 8 down to 2. Saving about €2,400 each month allowed the stacker to pay for itself in just over two months.” — Markus Huber, Logistics Manager, Stahlwerk Graz GmbH/Austria