Push-Type Pallet Changer: Swapping Pallets Without Tilting or Clamping

Executive summary Our push-type pallet changer swaps a pallet without turning the load at all. A hydraulic pusher slides the goods off the source pallet onto the target pallet, and the empty pallets are gathered automatically. The standard design handles loads up to 1,000 kg, which covers most pallets. Heavier builds are possible when the load has a cardboard base that can take the rubbing.

Table of Contents

How the push-type changer works

A forklift sets the loaded pallet on the infeed side at floor level. The target pallet waits on the other side, set level with the source pallet so the bottom layer cannot catch on its leading edge. A hydraulic cylinder drives the push plate against the side of the load and slides the whole stack across onto the target pallet. The machine then gathers the empty source pallet, so the operator does not have to lift it out by hand.

There is no inverting, tilting or clamping, so the goods stay upright the whole time. In our video, the only machine motion is the push stroke: the carton stack crosses to the new pallet while the forklift waits, and the forklift lifts it away a few seconds later. Because nothing turns, a cycle is mostly forklift time.

Forklift setting a pallet of shrink-wrapped bottled water at an orange push-type pallet changer
Push-type pallet changer. The forklift sets the load at floor level, and the pusher slides it onto the target pallet.

Why the load stays near 1,000 kg

The push plate has to overcome friction between the bottom layer and the pallet deck. That friction grows with load weight, so the design usually stays at or under 1,000 kg.

An illustrative estimate shows the scale. Push force is roughly the friction coefficient times the load weight. With a coefficient of 0.4 for cartons on wood, a 1,000 kg load needs about 3.9 kN, and a 2,000 kg load about 7.8 kN. The cylinder can deliver more force. The real limit is the bottom layer of the load, which takes all of that rubbing.

Which loads suit pushing

Load Push type? Reason
Cartons, shrink-wrapped packs, bagged goods Yes Stable stack, the base can take light rubbing
Load with a cardboard base or bottom sheet Yes, also above 1,000 kg on a custom build The cardboard takes the rubbing, not the product
Goods that must not tip or turn Yes The load never leaves the upright position
Bare product with a finish that must not scratch No Choose a tilting or inverting changer
Loose, unbonded stack Stretch wrap it first The push plate acts on one side only, so loose cartons can shingle or tip

Pushing is the mildest way to change a pallet for sensitive goods that must not be turned over. Mild here means no tilting; it does not mean no friction. If the bottom of your product cannot rub, a V-shape or 180° machine is the better choice.

Typical push-type jobs are swapping wooden shipping pallets for plastic pallets before goods enter a hygiene area, and bottled liquids that must stay upright.

Push type, V-shape or 180°

Machine How it frees the pallet Typical load
Push-type changer Slides the goods onto another pallet 1,000 kg
V-shape changer Tilts the load 90° onto its side 1.5 t standard, up to 3 t on special builds
180° inverter (FPFZ-1) Turns the load upside down Up to 1.2 t

Push-type changer data

Item Push-type pallet changer
Method Pushing, no inverting, tilting or clamping
Load 1,000 kg standard
Heavier builds Custom, for loads with a cardboard base that tolerate rubbing
Drive Hydraulic cylinder with durable valves
Loading Floor level
Empty pallets Gathered automatically after the change
Installation Standalone, or as part of a conveyor system

Safety and installation

The changer works at floor level, so forklifts or pallet trucks feed it without a ramp. Installed standalone, it serves one loading point. Built into a conveyor system, the pallet change happens in line, with no forklift move between the conveyor and the changer. The hydraulic valves are chosen to avoid oil leaks, and maintenance is simple.

The risk assessment covers the gap between the push plate and the load, which closes during the stroke, so we keep that zone guarded and away from the control point.

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 a push-type pallet changer

  • Heaviest load, and whether it is above 1,000 kg.
  • What the bottom layer is: cartons, cardboard sheet or bare product.
  • Can the base take light rubbing?
  • Source and target pallet sizes.
  • Standalone or in a conveyor line.
  • Pallets per hour needed.
  • Local power supply.

Engineering FAQ

Q: How heavy a load can the push-type changer handle? A: 1,000 kg, which covers most pallets. A custom build can go higher if the load has a cardboard base and tolerates the rubbing.

Q: Why not push heavier loads? A: Push force grows with weight, and all of it acts as friction on the bottom layer. Above about 1,000 kg, that rubbing starts to damage most products.

Q: Does the load get tilted or clamped? A: No. The goods stay upright and are slid across, so they suit loads that must not be turned over.

Q: Can it run inside a conveyor line? A: Yes. It works as a standalone unit or as part of a conveyor system, at floor level.

Q: What happens to the empty pallets? A: The machine gathers them automatically after each change, so the operator never lifts an empty pallet by hand.

Next step

We plan your push-type pallet changer in three steps:

  1. Submit your layout drawing with your pallet sizes, load weights and bottom-layer material to info@fhopepack.com.
  2. Receive a proposal within 48 hours, with the pusher design and line layout.
  3. Book a site survey to check the floor and the forklift path.

Sources

Last reviewed: 2026-10-04

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