Pallet Dispenser Ended

We are ATM Lazić, a Serbian manufacturer of industrial packaging machinery with 30+ years of experience serving EU clients. We need a complete mechanical design package for an automatic pallet dispenser for empty pallets, to be integrated at the infeed of our palletizing and stretch wrapping lines.
FUNCTION: The machine stores a stack of empty pallets in a vertical magazine and dispenses them one at a time onto a roller conveyor passing through the machine. Pneumatic side clamps hold the stack while the bottom pallet is released onto the conveyor. The unit must also support the reverse operation (stacking empty pallets from the conveyor into the magazine).

KEY SPECIFICATIONS:

Pallet sizes (two fixed formats): 1200 × 1000 mm and 1200 × 800 mm
Pallet orientation on conveyor: 1200 mm side runs transverse to conveyor travel direction (shorter side — 1000 or 800 mm — is parallel to conveyor flow)
Compatible with both wooden and plastic pallets (two-way and four-way)
Maximum number of pallets in magazine: 15 pcs
Maximum total stack weight: 450 kg (i.e., max ~30 kg per pallet)
Throughput: up to 200 pallets/hour (dispensing mode)
Operating modes: dispensing (de-stacking) AND stacking
Pallet transport access from up to three sides (flexible line integration)
Pneumatic actuation of side clamps/grippers

MECHANICAL DESIGN REQUIREMENTS:

Welded steel portal frame, floor-mounted with leveling feet
Pneumatic side clamp/gripper mechanism (4 clamps, two per 1200 mm side) to support the stack during single-pallet release — clamp positions are fixed since the 1200 mm side is common to both pallet formats
Minor format adjustment (1000 ↔ 800 mm) to be accommodated by adjustable or dual-position end stops/guides, not by moving the clamps
Open bottom to allow an underlying roller conveyor to pass through the dispenser (conveyor not part of this scope — design must provide mechanical interface dimensions only)
Magazine height sized for 15-pallet stack (approx. 2100–2400 mm depending on pallet thickness — confirm with designer)
Manual top/side loading provision for filling the magazine (forklift-loadable), with operator safety in mind
Safety-ready structure (customer-supplied perimeter fencing — design must accommodate standard guarding and light curtain at access opening)

UTILITIES & CONTROLS (reference — electrical handled in-house):

Power supply: 400 V / 50 Hz / 3-phase (low installed power, primarily pneumatic)
Air pressure: 6 bar
Recommended components: AZ or Festo pneumatics, Sick sensors, Siemens S7 PLC (mechanical design must specify compatible mounting and hose/cable routing)

DELIVERABLES:

Full 3D CAD model (preferred: SolidWorks 2022+; Inventor acceptable) + STEP export
2D manufacturing drawings (PDF + native) for all custom parts: welded frame, brackets, clamp arms, covers, sheet metal
General assembly drawings with overall dimensions
Complete Bill of Materials (editable Excel) with commercial component specifications and supplier references (European suppliers preferred)
Pneumatic schematic for clamp actuation sequence
FEA analysis of the frame structure at maximum stack load (450 kg)
Exploded views for maintenance manual

COLORS: RAL 7016 antrazite grey ( frame), RAL 1004 yellow (moving/safety parts).
COMPLIANCE: Design to CE Machinery Directive 2006/42/EC and EN ISO 13849-1 (PLd).
COMMUNICATION: English. Weekly review calls available. NDA on request. read less