Custom Pallet & Tote Handling Systems

Custom Engineered Solutions for Efficient Pallet & Tote Handling

Limited space, non-standard product loads, or specific handling maneuvers often require solutions that are custom engineered. Whether it’s a small or significant design change, Bastian Solutions explores innovative and creative approaches with our advanced technologies for reliable pallet handling, tote handling, palletizing and depalletizing.

Whether you need a stacker, dispenser or transfer car, Bastian Solutions can custom build the technology and solution to support your industry and operation needs. Manual pallet or tote handling is labor intensive and adds risk to both the product and your team. Our experts work with you to tailor the technology and operations for a more productive, safer, and improved operation flow.


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Some operations and products require creative approaches that traditional turnkey pallet  or tote handling solutions cannot fully satisfy. Such situations may involve challenges with:

  • Unwieldly products by weight and/or geometry (tall, heavy, unbalanced loads)
  • Non-standard or variable pallet sizes
  • Specific product handling requirements
  • Product or material QA/QC
  • Consistent and specific throughput needs
  • Facility structure and limited floor space
  • Operator safety and ergonomics

Minimal floor space

Over under conveyor systems are often used in manufacturing settings where floor space is limited. An over under conveyor is a two-tier conveyor system where the top conveyor holds full pallets and containers, while the lower conveyor handles empties. This vertical setup can be used for feeding empty or full pallets or totes to an operator. These easily customizable systems can operate with various belting options to accommodate specific product loads.

Forklift truck alternatives

Transfer cars, often leveraged in lean manufacturing operations, provide an efficient way to move pallets and large products between stations and positions. These floor-mounted cars use casters to smoothly pull heavy loads, thus serving as a solid alternative when forklift trucks or pallet movers aren’t the right option.

Pallet or tote dispensers and stackers are used to dispense and stack individual pallets or totes. These automated pallet handling or tote handling devices can be custom designed to meet your throughput needs and handle specific dimensions and types.

Custom Equipment Considerations

As we work together to design custom pallet handling and tote handling solutions, consider the following areas of your current operations:

  • Product travel distance and routes – inbound, storage, outbound
  • Productivity needs – throughput speed
  • Operator safety and safe handling of products
  • Racking type – double deep storage, FIFO (first in, first out), LIFO (last in, first out)
Over Under Conveyor Illustration

The Bastian Solutions’ custom automation team works with customers to determine feasibility and return on investment of all possible custom solutions. We use three main tools during the engineering and fabrication phase: 


Engineering Studies 

 By investigating your existing processes and exploring different configurations, we’re able to engineer the best custom solution.


Machine Simulations

 We create realistic models of your proposed operation using real-world data, rates, speeds and the logic associated with handling products.


Finite Element Analysis 

For large structural loads or precise handling requirements, we can test for the proper strength, rigidity or flexibility to reduce risks and confirm capabilities.



By demonstrating excellence for standardization and quality assurance in our manufacturing process and for our commitment to customer experience and satisfaction, Bastian Solutions’ custom automation division has achieved ISO 9001:2015 certification.

By responsibly managing the environmental impact of our manufacturing processes to improve our environmental performance and for our commitment to sustainability, Bastian Solutions’ custom automation division has achieved ISO 14001:2015 certification


See More Solutions


Custom Automation Brochure


Pallet Handling


Palletizing Equipment

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