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Home › Case Studies › Use-Case – SMITH Heavy-duty Electric Stacker

Use-Case – SMITH Heavy-duty Electric Stacker

  • Cut pallet handling time 40%
  • Eliminated double handling step
  • Reduced pallet damage by 75%
  • Freed one operator per shift
  • Payback achieved in under 2 months

The Challenge

A metalworking facility located near Graz processes approximately 120 finished pallets per day containing heavy steel parts. These pallets must be raised up to 4.5 metres into tall storage racks within extremely narrow aisles.

Previously, the site used a combination of manual pallet trucks and a semi-electric stacker. Heavier loads were typically moved in two stages: initially to a buffer area, then lifted by the semi-electric stacker. This two-step process was time-consuming, placed excessive strain on staff, and resulted in 8 damaged pallets per month due to unstable lifting and restricted visibility.

The management team sought a compact, robust electric stacker able to operate continuously for 5–6 hours, lift directly to 4.5 metres in a single movement, and handle 2-tonne loads safely within confined spaces.

Manual Process

Prior to automation, a single operator managed all finished goods using a manual pallet truck and a semi-electric stacker. Manoeuvring and aligning pallets in the tight aisles was slow, and each heavy pallet required two separate handling actions.

Before Automation:

The semi-electric stacker also demanded considerable physical effort to pump and position heavy items, increasing operator fatigue. Staff often reduced their pace for safety reasons, which further limited throughput during busy periods.

Automated Solution

The facility introduced a SMITH Heavy-duty Electric Stacker (2,000 kg, 4.5 metre lift) to replace both the manual truck and semi-electric stacker for finished goods. Its side-drive configuration and compact turning circle enabled direct access to high racking within the narrow aisles, eliminating the need for a buffer zone.

After Installing SMITH Heavy-duty Electric Stacker:

The integrated control handle, turtle speed function, and accurate MOSFETS drive enhanced precise positioning at height. A single operator can now manage the workload comfortably, with less physical effort and greater consistency, even during full 5–6 hour continuous shifts.

ROI Calculation

Investment:
Machine price: €5,499

Daily savings (labour):
Before: €225 per day
After: €135 per day
Labour savings: €225 − €135 = €90 per day

Daily savings (damage reduction):
Previous damage cost: €25 per day
Current 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
In summary: payback in just over 2 months

Conclusion

By combining two material handling processes into a single operation using the SMITH Heavy-duty Electric Stacker, the metalworking facility succeeded in reducing the time spent on pallet handling by 3.6 hours per day and lowered pallet damage by 75%. The outlay of €5,499 is recouped in a little over two months, and operators experience a safer and less physically demanding working environment.

“With the SMITH stacker, we reduced our daily pallet handling from 9 hours to 5.4 hours and decreased damage from 8 pallets to 2 per month. Saving approximately €2,400 each month meant the stacker paid for itself in just over two months.” — Markus Huber, Logistics Manager, Stahlwerk Graz GmbH/Austria