Published on: February 22, 2025 / update from: February 22, 2025 - Author: Konrad Wolfenstein
Smartes equipment: real-time data of pallets with PAL2REC-Use of artificial intelligence for data analysis of the sensor data-original picture: Fraunhofer iml / creative image: xpert.digital
Real-time tracking: Pallets become digital sources of information
Smart pallets: the transformation of intralogistics through real -time data and intelligent technology
In the complex world of logistics, where efficiency and transparency decisively decide on success and competitiveness, pallets play a central, although often underestimated role. These inconspicuous load carriers are the backbone of global goods and move countless goods through warehouses, production facilities and distribution centers every day. But their potential goes far beyond the pure transport function. The Fraunhofer Institute for Material Flow and Logistics IML has taken on the hidden possibilities and carried out a feasibility study as part of the "Pal2Rec" research project "Pal2Rec"-for "Pallet to Recognition"-which fundamentally changed the traditional understanding of pallets. The goal was ambitious: to prove that pallets can do more than just wear loads. They should "think" and provide valuable information about their logistical journey, the process steps and their movements in real time. The first results of this research work impressively confirm this vision and indicate an upcoming revolution in intralogistics.
Challenges of the logistics industry
We live at a time when the logistics industry is under enormous pressure to act more efficiently, more sustainably and economically. The optimization of processes, the reduction of costs and the minimization of environmental impacts have become central challenges. However, a major problem of many companies is the lack of transparency of their own logistical processes. There is often a "dark" in relation to the actual movements of goods, the utilization of resources and the efficiency of individual process steps. This missing information inevitably leads to inefficient processes, unnecessary costs and missed optimization potential. This is where Pal2Rec comes in to illuminate this darkness.
Intelligent sensors for pallets
The project's innovative approach is to equip pallets with intelligent sensors. These sensors, which can be integrated inconspicuously and robustly into the pallets, record a variety of data points that are of crucial importance for understanding the logistical events. Movements in real time, precise recording of bumps and vibrations, inclination and tilt angle- all of this information is recorded without gaps and placed in a comprehensive logistical context. Imagine that every palette becomes a "speaking" object that documents its own way through the logistics chain and provides valuable insights into the efficiency and quality of the processes.
Suitable for:
Artificial intelligence for data analysis
However, the sheer amount of data generated by this intelligent pallets would be worthless without an intelligent evaluation. This is where artificial intelligence (AI) comes into play. The researchers of Pal2Rec used the collected sensor data to train a AI that is able to identify complex movement patterns and to assign them to the corresponding activities in everyday logistics. Whether it is a matter of loading a palette with goods, storage in the high -bay warehouse, the transport with a forklift or the picking of articles - which AI learns to identify and interpret the characteristic movement profiles of any activity. The result is a kind of "activity profile" for each individual palette that provides detailed information about your tasks, the process steps and your movements.
Advantages of the data obtained
Julian Brandt, project manager of Pal2Rec and research assistant at Fraunhofer IML, emphasizes the enormous added value of this data: "The data provide valuable insights that support companies in specifically identify weaknesses and fully exploit optimization potential." But the advantages go far beyond pure process optimization. A particularly promising area of application is the forward -looking maintenance, also known as "predictive maintenance". The continuous monitoring of the pallet movements and the analysis of vibrations and loads can be recognized at an early stage before they even arise. For example, if a palette is repeatedly exposed to strong bumps or shows signs of material fatigue, this can be recognized in good time in order to pull the palette out of circulation and to avoid expensive failures or even accidents. This forward -looking maintenance not only contributes to increasing security, but also significantly reduces the costs for repairs and replacement procurement.
Selection of suitable sensor technology
Another important aspect of the PAL2REC project was the careful selection of suitable sensor technology. As part of the feasibility study, the researchers have intensively examined which sensors are best suited for this demanding application. A surprising and gratifying result was that even cost -effective sensor models can meet the requirements in many cases. This is a decisive factor for broad acceptance and implementation of technology in industry. Companies can therefore not only benefit from the numerous advantages of intelligent pallets, but can also do so in an economically portable framework. The investment in smart pallets thus promises a quick return on investment through efficiency increases, cost cuts and improved process quality.
Partnership and funding
The PAL2REC project is an impressive example of successful cooperation between research and science. It was carried out as a joint project with the renowned Chair for Funding and Balance (FLW) of the TU Dortmund. The project received financial support as part of the Mfund Innovation Initiative from the Federal Ministry of Digital and Transport (BMDV) with a funding amount of around 180,000 euros. This funding underlines the importance of the project for the further development of the logistics industry and the promotion of digital innovations in Germany. The previous results of the project are not only considered to be a complete success, but also serve as a strong incentive for the project partners to strive for follow -up promotion and to develop the promising technology and to convert it into practice.
Final event
On February 25, 2025, for everyone who is interested in the future of logistics and the potential of intelligent pallets. The official final event of the PAL2REC research project takes place on this day. Interested parties from industry, science and practice are welcome to take part in the presentation of the project results both on site and online and to discuss directly with the experts from the industry. This event offers a unique platform to inform yourself first -hand about the latest developments in the area of smart pallets and to establish valuable contacts.
More about it here:
Detailed insights into the PAL2REC project: objective, technology and advantages
The research project Pal2Rec (Pallet to Recognition) is more than just a feasibility study - it is an innovative initiative that has the potential to fundamentally change logistics. At the heart of the project is the vision of making pallets more intelligent in logistics and transforming them from passive load carriers into active sources of information.
Goal and concept: Autonomous activity recognition for intelligent logistics processes
The central goal of Pal2Rec is to examine how (euro) pallets can be integrated independently and proactively into logistical processes by sensor-based activity recognition. The project follows the approach of precisely capturing and interpreting movement data of pallets using sensors with the help of sensors, without being dependent on additional, costly and elaborate accompanying information such as camera images. The idea is that the palette itself becomes a "informant" and communicates its condition, its position and the passed processes in real time.
Technology and implementation: sensor equipment, AI-based data analysis and activity profiles
In order to achieve this ambitious goal, Pal2Rec relies on a combination of the latest sensors and artificial intelligence. The technological implementation essentially includes the following steps:
Sensor equipment of the pallets
In the first step, conventional pallets - especially Euro pallets that represent the industrial standard - are equipped with intelligent sensors. These sensors are able to measure a variety of physical quantities that provide information about the movement and condition of the palette. This typically includes acceleration sensors, gyroscopes, position sensors and, if necessary, sensors for recording temperature, humidity or vibrations. The sensors are integrated into the palette in such a way that they are robust compared to the rough conditions in everyday logistics and do not affect the functionality of the palette. The energy supply of the sensors can be carried out, for example, by small batteries or energy harvesting technologies, which gain energy from the movement or vibration of the palette.
AI use for data interpretation
The data collected by the sensors are continuously collected and transferred to a central evaluation unit. This is where artificial intelligence comes into play. The collected raw data of the sensors are initially not very meaningful. Only through the intelligent processing and analysis with the help of AI do you become valuable information. The AI is trained to identify complex movement patterns and assign these specific logistical activities. The KI is training with the help of large amounts of sensor data that are recorded in real logistics environments. Through machine learning, the AI learns to distinguish the characteristic movement profiles of different activities such as loading, unloading, storing, outsourcing, transport with forklifts, picking, etc.
Creation of activity profiles
The result of the AI-based data analysis is the creation of a detailed "activity profile" for each individual palette. This profile documents precisely, which logistical processes have passed the palette, when and where these processes have taken place and how long they took. The activity profile thus contains valuable information about the entire "life story" of the palette in the logistics chain. This information can be used for a variety of applications, from process optimization to inventory management to quality assurance.
Advantages and applications: process optimization, predictive maintenance and cost efficiency
The implementation of intelligent pallets based on PAL2REC technology offers companies a variety of advantages and opens up new fields of application in logistics:
Process optimization and increase in efficiency
Through the detailed recording and analysis of the pallet movements, companies receive a transparent insight into their logistical processes. Weaknesses, bottlenecks and inefficiencies become visible and can be remedied in a targeted manner. For example, unnecessary waiting times, empty trips or cumbersome transport routes can be identified and optimized. The real -time data of the smart pallets enable a dynamic adjustment of the processes and a more flexible reaction to unforeseen events. This leads to a significant increase in efficiency, reducing the lead times and optimizing the material flow.
Predictive maintenance and reduction of downtimes
As already mentioned, the continuous monitoring of the pallet movements and the analysis of stress and vibrations enables early detection of potential damage. Through predictive maintenance, companies can pull pallets out of circulation in good time before there are failures, damage to goods or even accidents. This not only reduces the costs for repairs and replacement procurement, but also minimizes downtimes and production interruptions. The predictive maintenance thus contributes to the higher availability of the pallets and an overall more stable and more reliable logistics.
Improved inventory management and warehousing
The intelligent pallets provide precise information about your location and content. This enables improved inventory management and warehousing. Companies have a precise overview of the whereabouts of their goods and can optimize their inventory at any time. The search for certain pallets or articles in the warehouse is significantly simplified and accelerated. The inventory can also be made more efficient by automatic recording the pallet movements and locations.
Quality assurance and damage prevention
By recording bumps, vibrations and extreme temperatures, the smart pallets can also contribute to quality assurance and damage prevention. If sensitive goods are transported, the sensor data can provide information about whether the goods were treated improperly during transport and may have been damaged. This enables early damage detection and the initiation of suitable measures to minimize damage.
Cost efficiency and economy
Although the implementation of intelligent pallets initially requires investments in sensors and IT infrastructure, it promises high cost efficiency and economy in the long term. The initial investment costs generally significantly significantly significantly exceed the savings through process optimization, predictive maintenance, improved inventory management and damage prevention. In addition, the Pal2Rec feasibility study has shown that also inexpensive sensor models can meet the requirements, which makes technology attractive for small and medium -sized companies.
Sensor-based activity detection in detail: data acquisition, AI evaluation and activity profiles
The sensor-based activity detection for pallets developed as part of the PAL2REC project is based on a sophisticated interaction of sensors, data transmission, artificial intelligence and data analysis. In the following, the individual steps of this process are explained in more detail:
Comprehensive sensor equipment for detailed movement data
The first step is the equipment of the pallets with a variety of sensors that can record detailed movement data. Various sensor types are used, each measuring specific aspects of the pallet movement:
Acceleration sensors
Capture accelerations in three spaces and provide information about the dynamics of the movement, such as starting, braking or accelerating the palette.
Gyroscopes
Measure rotary rates around three axes and thus capture rotation and rotations of the palette, for example when driving or turning with a forklift.
Lating sensors (inclination sensors)
Determine the orientation of the palette in the room and capture the inclination and tilt angle, for example when lifting or setting the palette.
Optional: environmental sensors
Depending on the application, sensors can also be used to record temperature, air humidity, vibrations or light intensity in order to document further relevant environmental conditions.
Continuous data acquisition for complete information
The sensors continuously collect data about the activities and movements of the palette. The measurement data are recorded and saved at short time intervals to ensure a complete recording of information about the entire logistics process. The data transmission from the sensors to the central evaluation unit can be wirelessly via radio technologies such as Bluetooth, WLAN or Narrowband-Iot (NB-IoT). NB-IoT is particularly useful for applications in large warehouses or outdoors, as it has a high range and energy efficiency.
AI-based evaluation for pattern recognition and activity assignment
The collected sensor data are used to train artificial intelligence (AI). This AI is designed to identify complex movement patterns and assign them specific logistical activities. The AI training is carried out with the help of machine learning, especially with deep learning processes. The AI are presented large quantities of sensor data, which are annotated with the associated logistical activities (e.g. "loading", "storage", "forklift trip"). The AI learns to identify and generalize the characteristic movement profiles of any activity. After training, the AI is able to analyze unknown movement patterns and to recognize the underlying logistical activity with high accuracy.
Creation of activity profiles for comprehensive process information
Based on the evaluated data and the recognized activities, a detailed activity profile of the palette is created. This profile contains information about various logistical processes that the palette has passed through, such as:
Load and unload
Detection of loading and unloading processes, including time stamps and duration.
Storage and outsourced
Identification of storage and outsourcing processes in the warehouse, including the storage location (if supplemented by additional localization technologies).
Transport with forklift
Detection of forklift trips, including a route, speed and driving behavior.
Pick up
Identification of picking processes, including commissioned article (if combined with additional identification technologies).
Wait and standstill
Recording waiting times and standards in various process steps.
Interpretation and analysis for process optimization
The recognized patterns and activities are used to interpret and analyze logistical processes. The activity profiles provide companies valuable insights into their logistical processes and enable weaknesses to identify vulnerabilities in their processes and to identify potential for optimization. For example, companies can analyze which process steps are particularly time -consuming, where there are unnecessary waiting times or where material flows are inefficient. Based on these findings, targeted process optimization measures can be initiated.
Proof of feasibility for autonomous and transparent logistics
The PAL2REC project aims to provide the proof of feasibility that logistical processes can be interpreted and reproducible by the additional sensor data, without being dependent on external accompanying information such as camera images or manual data acquisition. The autonomous activity detection of the smart pallets significantly increases the transparency in the logistics chain. Companies receive a comprehensive and real-time insight into their goods movements and can optimize their processes data-based.
Smart pallets as the key to the logistics of the future
This innovative technology transforms pallets from simple charge carriers into intelligent sources of information in the logistics chain. Smart pallets are more than just a trend - they are a key to the logistics of the future. They enable improved transparency, efficiency and sustainability in logistical processes and help to manage the challenges of modern logistics. The Pal2Rec project of the Fraunhofer IML and the TU Dortmund has laid an important foundation for the broad implementation of this promising technology and impressively shows the potential of intelligent pallets for revolutionizing intralogistics. The future of logistics is smart - and pallets play a crucial role.
Suitable for:
Your global marketing and business development partner
☑️ Our business language is English or German
☑️ NEW: Correspondence in your national language!
Konrad Wolfenstein
I would be happy to serve you and my team as a personal advisor.
You can contact me by filling out the contact form or simply call me on +49 89 89 674 804 (Munich) . My email address is: wolfenstein ∂ xpert.digital
I'm looking forward to our joint project.