Eight years of strategic automation investment has transformed Pallet Broker LLC from a labor-intensive operation into one of the most technologically advanced pallet companies in the American West.
People are expensive. Labor availability is tightening. The companies that invest in automation now will have a structural cost advantage that compounds over time. We made that bet starting in 2017 — and it's paying off.
Our Las Vegas facility runs a state-of-the-art AMS automated repair line installed in 2024. The system processes 4,300–4,400 pallets per shift compared to 3,500 under the previous manual system — a 26% productivity increase with a smaller, more capable team.
Our Sparks manufacturing HQ pioneered our automation journey in 2017 with an AMS repair line. We've since added a Robotic Pallet Dismantler and Urban Sawmill from Alliance Automation for combo pallet production.
Automation is only as good as the data it produces. Our PalMate enterprise resource planning software connects both facilities, giving management real-time visibility into inventory, production, and supplier quality.
Every pallet is barcoded and tracked from destacker through repair to stacking. We know the supplier, the repair technician, and the final grade for every single pallet processed.
We know exactly which suppliers send ready-to-go Grade A pallets versus pallets requiring repair. This data drives smarter sourcing decisions and better cost management across our entire supply chain.
Management can login and see real-time inventory numbers at either facility, even remotely. This cross-facility visibility enables better resource allocation, faster customer quotes, and more reliable delivery commitments.
The goal of our automation program was never just to reduce headcount. It was to make the remaining jobs better, safer, and more attractive — expanding the pool of people who can do the work.
Before automation, labor was Pallet Broker's biggest operational challenge. Physical strain limited the pool of workers who could do the job, turnover was high, and overtime was chronic.
Today, the company receives more job applications than ever — employees are bringing family members in to apply. The reduced physical demands have broadened hiring significantly.
"The new AMS line has enabled us to significantly boost production while making the jobs safer."— Matt Stephan, President & Co-Owner, Pallet Broker LLC Read the Full Story →
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