Executive summary Stacking aluminum profiles by hand ties up two people per line and scratches the finished surface. Our automatic aluminum stacker in this video picks layers of profiles off the conveyor with a yellow arm on a blue gantry and stacks them on the pallet below, while the workers move to watching the line. Stack height and weight follow from the layer count and the profile weight. We set both per project.
Table of Contents
- What the video shows
- How the stacker cycle works
- Stack height and weight per pallet
- Hand stacking and machine stacking
- Controls and safety
- Selection checklist for an aluminum profile stacker
- Engineering FAQ
- Next step
- Related reading
- Sources
What the video shows
At the start of the clip, two workers in red helmets and blue workwear lift a layer of coloured profiles off the conveyor by hand and carry it to a pallet. Then the stacker takes over: the yellow arm on the blue gantry reaches down, grips the profiles on the conveyor, lifts them, moves across and lowers them onto the pallet.
The cycle repeats, and the stack grows from one layer to four. The workers now stand by the conveyor and watch. Later shots show the long conveyor carrying silver profiles to the stacking area.
How the stacker cycle works
| Step | What happens |
|---|---|
| Arrive | A layer of profiles reaches the pick position |
| Grip | The yellow arm comes down and grips the layer |
| Move | The arm lifts and travels to the pallet |
| Place | The layer is set on the stack |
| Return | The arm goes back for the next layer |
The arm sets each layer down rather than dropping it, so finished surfaces do not rub.
Stack height and weight per pallet
Illustrative example:
| Item | Value |
|---|---|
| Layer height (illustrative) | 50 mm |
| Layers per stack (illustrative) | 20 |
| Stack height, 20 × 50 | 1,000 mm |
| Layer weight (illustrative) | 75 kg |
| Stack weight, 20 × 75 | 1,500 kg |
We check stack height against your forklift and storage, and stack weight against the pallet and floor.
Hand stacking and machine stacking
| By hand | With the stacker | |
|---|---|---|
| People at the end of line | Two lifting layers | Watching the line |
| Surface marks | Rubbing as layers slide | Layers set straight down |
| Stack shape | Depends on the crew | Even layers |
| Pace | Limited by the crew | Set by the arm cycle |
Spacers between layers can be added by hand or by a spacer feeder. For tying profiles into bundles before stacking, see our aluminum profile bundle tying machines; for the full end-of-line, see our high-speed aluminum profile packing machine.
Controls and safety
The arm travels over the conveyor and the pallet and comes down with force. Keep people out of the stacking area while the stacker runs, and change pallets only with the stacker stopped and isolated.
The standards that apply depend on the destination market. For CE markets, ISO 12100 sets the risk-assessment method and EN 415-10 sets general requirements for packaging machines.
Selection checklist for an aluminum profile stacker
- Profile length, section and weight per metre.
- Profiles per layer and layer height.
- Layers per stack and stack weight.
- Spacers between layers.
- Line output.
- Building space and pallet handling.
Engineering FAQ
Q: How does the stacker protect profile surfaces? A: It sets each layer straight down instead of sliding it.
Q: How high and heavy is a stack? A: It follows from layer count, layer height and layer weight, set per project: our example of 20 layers at 50 mm and 75 kg gives 1,000 mm and 1,500 kg.
Q: What do the workers do once the stacker runs? A: They watch the line instead of lifting layers.
Q: Can spacers be added between layers? A: Yes, by hand or with a spacer feeder.
Q: What sets the stacking pace? A: The arm cycle: grip, move, place and return.
Next step
We plan your aluminum profile stacker in three steps:
- Submit your layout drawing with profile sizes, weights and output to info@fhopepack.com.
- Receive a proposal within 48 hours, with the stack pattern and layout.
- Book a site survey to check the end of line and pallet handling.
Related reading
- Aluminum profile packing
- Video: automatic aluminum profile packaging line for paper packing and stacking
- Video: aluminum horizontal wrapping machine with spacer feeder
Sources
- Machine content: FHOPE engineering team, 2026-10-04
- Stack example: our worked example, illustrative values
- Machine in action: our video on YouTube
- Standards scope: ISO 12100:2010, EN 415-10:2014
Last reviewed: 2026-10-04
