SafeStackers patents empty pallet stacking machine

SafeStackers recently announced its newly-patented invention for warehouse safety and logistics. Engineered for the receiving end of warehouse operations, this American-made, automated machine stacks and unstacks pallets quickly and safely, reducing the need for manual stacking and the risk of serious workplace injuries.

According to OSHA and industry data, manual pallet stacking remains one of the most dangerous and inefficient tasks in warehouse operations. Pallet-related accidents are among the most common and costly warehouse injuries, often resulting in sprains, fractures, crush incidents, and long-term worker disability. With over two billion pallets in circulation across more than 100,000 U.S. warehouse facilities, the risks - and the costs - are enormous.

SafeStackers said it addresses this problem at its root, using a programmable control system and sensor-guided forks to safely and uniformly stack and unstack pallets, removing workers from harm’s way. Immediate benefits include labor savings and increased efficiency by freeing workers and forklifts for higher-value tasks.

“This isn’t just about automation-it’s about safety,” said Nic Wettersten, SafeStackers CEO and founder. “Manual pallet stacking is a high-risk, labor-intensive task that leads to thousands of injuries each year. SafeStackers is designed to prevent that.”

Wettersten is building on the legacy of his father - a Swedish Ph.D. in electrical and mechanical engineering who pioneered pallet automation in Europe. That earlier system was hugely successful with over 18,000 units in use in warehouses before the business was sold. SafeStackers is a more advanced, U.S.-patented system tailored for high-volume American warehouse environments. It’s been in development for years and is now ready for rollout.

Commitment to U.S. manufacturing and job growth

According to industry data, there are at least 38,600 active warehousing businesses and over 100,000 warehouse buildings across the U.S. These facilities face rising insurance premiums, labor shortages, and high injury-related costs. SafeStackers said it can offer immediate benefits:

• Injury Reduction - Remove workers from high-risk stacking

• Cost Savings - Cut labor and forklift operating costs

• Operational Efficiency - Handle large pallet volumes quickly and accurately

SafeStackers said it is committed to U.S. manufacturing and job growth. Headquartered in the greater Charlotte, North Carolina metro area, the company plans to build a manufacturing facility in Marshville that could employ 100–200 workers.

“Our vision is to establish a national sales and service dealer network,” said Steve Weintz, founder of SBW Ventures, Inc., the firm spearheading U.S. commercialization. “We’ll begin by focusing on the Charlotte marketplace but expect to be selling and shipping SafeStackers nationwide within months.”

SafeStackers said it can provide CFOs, warehouse managers, and safety managers in large retail, logistics, and food service operations a cost-effective way to cut liability and boost operational performance at scale.