LAYERCOUNT
Automated Pallet Counting for Sheets, Stacks and Layers
LayerCount counts the layers and sheets in stacked product on pallets, from corrugated sheets and carton blanks to boards and panels, so every pallet you ship, receive or pick from has a verified count instead of an estimate.
- Mobile or fixed system
- Laser-marked pick quantities straight on the stack
- Data stays on-premise, with no reliance on cloud services
AUTOMATED PALLET COUNTING
What is automated pallet counting?
Automated pallet counting uses cameras and image analysis to count the layers, sheets or units stacked on a pallet. LayerCount images the edge of the stack, finds each boundary between layers and reports the exact count, so stacks no longer have to be counted by eye or estimated from height or weight.
What LayerCount counts
HOW IT WORKS
How LayerCount counts layers on a pallet
LayerCount looks at the structure of the stack itself, not its height or weight. Industrial cameras and lighting capture the edge profile of the stack, and image analysis finds each transition between layers.
- Blue dashed lines: the camera's view of the stack edge.
- Green ticks: layer boundaries found by the image analysis.
- Purple line: the laser mark showing where to pick a requested quantity.
CONFIGURATIONS
Mobile or fixed pallet counting system
| Mobile system | Fixed system | |
|---|---|---|
| Where it works | Rolled to pallets anywhere in the plant or warehouse | At a set station, such as a line, dock or wrapping area |
| Best for | Counting pallets where they sit, audits and picks across a facility | High-volume verification at one point in the flow |
| Integration | Stand-alone, with results on its own HMI | Stand-alone or integrated with an existing line |
| Picking | Laser-marked pick quantities on the stack | Laser-marked pick quantities on the stack |
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Either way, the same LayerCount platform is configured for your sheet sizes, thicknesses and materials by adjusting the cameras, optics and software. It is custom developed and built in-house in the US.
PALLET COUNTING METHODS
Why count layers instead of measuring height or weight?
| Method | How it counts | Weak point |
|---|---|---|
| Counting by eye | A person counts the layers on the stack | Slow, tiring and error-prone on tall stacks of thin sheets |
| Height ÷ thickness | Stack height divided by nominal sheet thickness | Thickness varies with grade, moisture and compression, so the count drifts |
| Weight | Pallet weight divided by sheet weight | Sheet weight varies with material and moisture; pallets and wrap add weight |
| LayerCount vision counting | Cameras find each layer boundary in the stack edge | Counts the actual layers, with mixed heights and stack patterns |
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Worked example: how a height estimate goes wrong
A stack of corrugated sheets is 1,200 mm tall. With a nominal sheet thickness of 4.0 mm, the height method says 1,200 ÷ 4.0 = 300 sheets. This lot actually averages 4.1 mm, so the stack really holds about 1,200 ÷ 4.1 ≈ 293 sheets: 7 fewer than the estimate, a 2.3% error on every pallet. Counting the layers themselves removes that guesswork.
APPLICATIONS
Where automated pallet counting pays off
LayerCount is built for packaging plants, corrugated converters and warehouses that want to cut manual counting, eliminate recounts and avoid shipping pallets with the wrong quantity.
SEE IT RUN
LayerCount demo video
The software shows the stack image, the layers it found and the count, on an HMI at the pallet.
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Counting systems guide
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FAQ
Automated pallet counting FAQs
What is automated pallet counting?
Automated pallet counting uses cameras and image analysis to count the layers, sheets or units stacked on a pallet, instead of counting by eye or estimating from height or weight.
How does LayerCount count layers?
Industrial cameras and lighting image the edge of the stack, and image analysis finds each boundary between layers. The count is shown on the HMI, and pick quantities can be laser-marked on the stack.
What can LayerCount count?
Corrugated sheets and carton blanks, folding cartons and paperboard, boards, panels and partitions, and other palletized products that form clear layers, such as tires and filters.
Is LayerCount mobile or fixed?
Both are available. The mobile system is rolled up to pallets anywhere in a facility; the fixed system is installed at a station such as a line, dock or wrapping area.
Why not estimate sheet counts from stack height?
Sheet thickness varies with grade, moisture and compression, so dividing height by nominal thickness drifts. A small thickness difference can shift the count by several percent on every pallet.
Does LayerCount send data to the cloud?
No. Data stays on-premise, without reliance on third-party APIs or cloud systems.
FREE CONSULTATION
Stop counting stacks by eye
Tell us what you stack, how pallets move through your plant and where counts matter. We will recommend a mobile or fixed LayerCount and show it counting product like yours.
- Custom developed and built in-house in the US
- Engineering automation and vision systems since 1997
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© Copyright 2026 by Coleman Technologies, Inc. DBA Sciotex