LayerCount – Automated Counting of Cardboard Stacks on Pallets

Count the Stacks in your Warehouse Faster

Automated Counting of Layered Sheets and Stacks

LayerCount is a specialized vision‑based counting system from Sciotex that automatically counts layers and sheets of cardboard on pallets with high speed and accuracy. By using machine vision instead of manual counting, LayerCount helps packaging and manufacturing operations eliminate miscounts, reduce labor, and increase throughput.

Automatically counts layers or sheets of corrugated on stationary pallets.
Works with mixed pallet heights and varying stack patterns.
Counts stacks quickly and assists with pick counts with laser marking.
Can integrate with existing lines or as an independent system to improve QC.
Custom developed and built in-house here in the US.
Data remains on-premise without relaince on 3rd party APIs or cloud systems.

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Counting Consultation

Mobile System

Fixed System

What LayerCount Counts

LayerCount is engineered for applications where stacked materials must be counted quickly and reliably at the pallet or unit‑load level.

Corrugated sheets and carton blanks stacked on pallets.
Bundled or stacked folding cartons and paperboard.
Stacks of boards, panels, or partitions.
Other palletized products that form clearly defined layers.
Can be configured as a mobile or fixed system.

The same LayerCount platform can be configured for different sizes, thicknesses, and materials by adjusting cameras, optics, and software parameters.

How LayerCount Works

LayerCount uses industrial cameras and lighting to capture images of the palletized stacks, then applies specialized layer‑counting algorithms to determine the exact number of layers or sheets.

A pallet enters the LayerCount inspection zone or is positioned within view of the camera.
Vision algorithms detect transitions between layers and calculate the layer count.
Results are reeported to the onboard HMI and
Picking quantities can be laser marked to easily determing the quantity to be picked.

Vision‑based counting allows LayerCount to handle variations in stack height, minor edge irregularities, and different cardboard grades better than manual visual inspection.

Technology and AI Capabilities

Unlike simple height measurements or weight‑based counting, LayerCount uses vision‑based analysis of the stack structure itself.

High‑resolution industrial cameras capture clear images of the stack’s edge profile.
Optimized lighting enhances contrast at layer boundaries.
Image processing locates edges and repetitive patterns corresponding to individual sheets or layers.
AI‑assisted algorithms can be applied to improve robustness when edges are worn, irregular, or partially obscured.

Performance and Throughput

LayerCount is designed for high‑throughput environments where pallets must be processed quickly without sacrificing accuracy.

Representative capabilities:

High‑speed counting of full pallets with minimal cycle‑time impact.
Near‑real‑time count results suitable for in‑line verification.
Accuracy tuned to your layer thickness, pallet format, and tolerances.
Configurable alarms when counts fall outside expected values or targets.

Automating layer counting helps reduce manual errors, eliminate recounts, and avoid shipping pallets with incorrect quantities.

LayerCount Demo Video

With LayerCount you get:

Laser-marked picking from stacks for production.
Verifying sheet counts before shipping, receiving.
Confirming layer counts before stretch‑wrapping pallets.
Auditing pallet contents for inventory, WIP tracking, or customer documentation.