Skip to main content

Case Study: Pallet Recognition System for Autonomous Forklifts

How We Improved Safety and Efficiency of Autonomous Forklifts with AI. In fast-paced warehouse environments where precision and speed are critical, we developed an AI-powered pallet recognition system for a leading mobile robot manufacturer. The result? Autonomous forklifts now handle even unpredictably placed pallets faster, safer, and more efficiently.

Client: Leading manufacturer of mobile robots and AGVs
Industry: Industrial Automation / Robotics / Logistics

🎯 The Challenge

In dynamic warehouse environments, pallets are often misaligned or placed unevenly in pallet nests. This posed a significant challenge for autonomous forklifts, leading to operational delays, handling errors, and safety risks.

🧠 The Goal

Develop a reliable AI-powered vision system capable of detecting and localizing pallets accurately – even when their position is unpredictable or irregular.

🛠️ Our Solution

We implemented a custom-built computer vision system, integrated directly with the client's AGV platform. Our approach combined:

  • Real-time pallet detection in variable industrial conditions
  • Robust localization, regardless of placement or angle
  • Seamless integration with autonomous forklifts

Thanks to advanced AI algorithms and industrial-grade vision pipelines, the system consistently identifies pallet positions with high accuracy.

📊 The Results

✅ 95% reduction in warehouse accidents – AI-based detection minimized risks related to misaligned pallet handling
✅ 35% cost savings – Outsourcing AI development proved significantly more cost-effective than building an in-house AI team
✅ Higher operational efficiency – Faster pallet detection led to smoother 

AGV cycles and safer workflows

🚀 Ready to power your operations with AI?

If you're planning a project in AI/ML, computer vision, or autonomous logistics, we’re here to help.

📩 Let's talk – our team at Inovatica AGV designs scalable AI solutions tailored to real-world industrial challenges.

AI Pallet result