Pallet processing system

Abstract

System and method for processing pallets for reuse, including obtaining, at an automated system, inspection data for each pallet in a batch of pallets based on an inspection of each pallet performed by an automated pallet inspection machine; and assigning, using the automated system, a pallet evaluation metric for each pallet based on the inspection data obtained for the pallet; and assigning, using the automated system, a batch evaluation metric for the batch of pallets based on the pallet evaluation metrics assigned to each pallet in the batch of pallets.

Description

PALLET PROCESSING SYSTEMRELATED APPLICATIONS

[0001] This application claims the benefit of and priority to United States Provisional Patent Application No. 63 / 561,510, filed March 5, 2024, the content of which is incorporated herein by reference.FIELD

[0002] This disclosure relates generally to a system and method for processing pallets.BACKGROUND

[0003] Pallets (also called skids) have become ubiquitous in the shipping and transportation of goods and materials. A pallet is the structural foundation of a unit load, which allows handling and storage efficiencies. Generally, a pallet is a flat transport structure, which supports goods in a stable fashion while being lifted by a forklift, a pallet jack, a front loader, a jacking device, or an erect crane. While most pallets are wooden, pallets can also be made of plastic, metal, paper, and recycled materials.

[0004] Pallets come in a wide range of sizes and configurations. For example, TABLE 1 below sets out examples of pallet sizes that are commonly used in North America:TABLE 1: Pallet Sizes and UsesDimensions Width x Length Example Industries Inches40 x 48 Grocery, many others42 x 42 Telecommunications, paint48 x 48 Drums48 x 40 Military, cement48 x 42 Chemical, beverage40 x 40 Dairy48 x 45 Automotive44 x 44 Drums, chemical36 x 36 BeverageBeverage, shingles,48 x 36 packaged paper

[0005] Two common wooden pallet configurations are "stringer" and "block" pallets, examples of which are shown in FIGs. 1A and IB respectively. Stringer pallets use a frame of three or more parallel pieces of timber (called stringers) that support top and bottom deck boards. Block pallets are made with solid, square blocks between the top and bottom decks. The number of top and bottom deck boards used in pallets, and other configuration parameters, can vary depending on the intended use. FIGs. 1A and IB illustrate examples of components that make up pallets and related configuration parameters. A non-exhaustive list of pallet attributes and their respective descriptors are set out in the following TABLE 2:TABLE 2: Pallet AttributesPallet Attributes DescriptorsConfiguration (110A, HOB) Type: Block or Stringer Length 112 and Width 114 Dimensions (typically in inches in North America) Overall height 116 Dimension Opening height 118 DimensionPallet Attributes DescriptorsInternational Plant Protection Committee (IPPC)Treatment Code 136 treatment codeType: Wood (and in some cases, Wood Grade) or PlasticPainted Yes / No, and / or Color TypeTop lead deckboard 120 DimensionsTop Deckboards (other) 121 Dimensions, Number, PatternTop deck opening 138 WidthButted end boards 134 Yes / NoBottom deckboards 130 Dimensions, NumberStringer boards 126 Dimensions, NumberOuter stringer (runner) 132 Dimensions, NumberWheel opening 124 DimensionsBlock 128 Dimensions, NumberIndicator of Overall Pallet Quality - e.g., GradePallet Grade A, Grade B

[0006] As noted in the above table, in some examples, pallet attributes can also include an overall pallet grade, for example "Grade A" could be associated with a pallet that is in excellent condition and appears suitable for display on a retail floor; and "Grade B" could denote a pallet that is structurally solid and suitable for use in a supply chain, but has visible indications of previous repairs.

[0007] The treatment code 136 identified above may, for example be an International Plant Protection Committee (IPPC) treatment code. As known in the art, such codes are uniquely assigned to a treating entity (e.g., a pallet manufacturer or repair facility) that has been licensed by the IPPC to perform decontamination treatment of wood products and can include the information "CC- RC-XXXXXX-TT", where "CC-RC" identifies a country code and region code thatidentify where the treatment facility is located, "XXXXXX" is unique code that identifies the heat treatment facility (and thus a source of the treated product), and "TT" is a two letter identifier that identifies a type of treatment (e.g., HT=heat treatment; MB = methylbromide; DB = debarked). In the case of pallets, the heat treatment identifier will typically be "HT". FIG. 2 illustrates an example of a treatment code 136 stamp that can be applied to a pallet stringer or block.

[0008] Pallets are frequently collected and reused. Used pallets can suffer from various defects, including for example missing, broken, or damaged components or features including but not limited to one or more of: protruding nails; visible contamination (damp spots, mold, stains, discoloration, adhered debris); rotten spots; obscured labelling (e.g., sprayed or painted over treatment code); and broken, cracked, missing, waning and / or chipped boards and / or blocks.

[0009] The wide range of pallet sizes and configurations, the differing physical conditions of used pallets, and the geographical dispersion of pallets can introduce logistical challenges that makes collection and reuse inefficient to the point that many pallets end up getting needlessly discarded or otherwise diverted from the shipping industry. This requires new pallets to be manufactured and introduced into the shipping cycle, which can be expensive and is also detrimental to the environment. Inefficiencies within the pallet ecosystem are exacerbated by the sheer volume of pallets within the system, the relatively low incentives to reuse individual pallets, and the high cost of human labor. For example, a large scale pallet processing facility can process thousands and even tens of thousands of pallets or more each day. Human based processing systems simply cannot match the volume of incoming pallets to ensure data is efficiently tracked and subsequently used to improve system efficiency to maximize the number of pallets that are diverted from waste throughout the entire pallet ecosystem.

[0010] There is a need for improved systems and methods for processing used pallets that will improve efficiencies and reduce the number of pallets that are directed out of the shipping industry.SUMMARY

[0011] According to example aspects, methods and systems for processing pallets are disclosed that can increase efficiencies in the reuse of pallets and decrease waste and costs in the shipping industry.

[0012] According to a first aspect of the current disclosure, a method for processing pallets is described. The method includes obtaining, at an automated system, inspection data for each pallet in a batch of pallets based on an inspection of each pallet performed by an automated pallet inspection machine; assigning, using the automated system, a pallet evaluation metric for each pallet based on the inspection data obtained for the pallet; and assigning, using the automated system, a batch evaluation metric for the batch of pallets based on the pallet evaluation metrics assigned to each pallet in the batch of pallets.

[0013] According to some examples of the first aspect, the method includes determining, using the automated system and based on the batch evaluation metric, a supplier evaluation metric for a supplier of the batch of pallets; and storing the supplier evaluation metric in association with a batch supplier identifier for the supplier in a historic supplier evaluation metric database that comprises records of supplier evaluation metrics determined in respect of multiple different suppliers.

[0014] According to one or more of the preceding examples, the method includes using the automated system and based on the batch evaluation metric,automatically determining a compensation amount for electronic transfer for the supplier.

[0015] According to one or more of the preceding examples, the method includes obtaining, at the automated system, batch data for a potential batch of pallets, the batch data indicating: (i) a batch supplier identifier that identifies a supplier of the potential batch of pallets; (ii) an estimated quantity of pallets included in the potential batch of pallets; and (iii) a geographic location of the potential batch of pallets; determining, using the automated system and based on the batch supplier identifier, if the historic supplier evaluation metric database includes a supplier evaluation metric associated with the supplier of the potential batch of pallets and if so, retrieving the supplier evaluation metric associated with the supplier of the potential batch of pallets; assigning, using the automated system, a potential batch evaluation metric for the potential batch of pallets based on: (i) the retrieved supplier evaluation metric; (ii) the estimated quantity of pallets; and (iii) the geographic location of the potential batch of pallets; and performing, using the automated system and based on the assigned potential batch evaluation metric, an action in respect of the potential batch of pallets.

[0016] In some examples, the action includes, when the assigned potential batch evaluation metric is determined to exceed a threshold, one or more of: automatically causing an electronic notification to be generated for the supplier of the potential batch of pallets indicating acceptance of the potential batch of pallets; automatically causing an electronic notification to be generated for the supplier of the potential batch of pallets indicating a potential compensation based on the assigned potential batch evaluation metric; and automatically issuing a dispatch notice, including a unique batch identifier, for a vehicle to travel to the geographic location of the potential batch of pallets for pickup thereof.

[0017] In some examples, the action includes: when the assigned potential batch evaluation metric is determined to not meet an evaluation metric threshold, one or more of: automatically causing an electronic notification to be generated for the supplier of the potential batch of pallets indicating rejection of the potential batch of pallets; and automatically causing an electronic notification to be generated for the supplier of the potential batch of pallets indicating a charge for picking up the potential batch of pallets.

[0018] In some examples, the inspection data for each pallet includes parameters indicating of one or more of the following: pallet configuration attributes, including one or more indicators of: a pallet type indicating if the pallet is a stringer pallet or a block pallet; a length of the pallet; a width of the pallet; a height of the pallet; a number of top deck boards; a number of bottom deck boards; spacing between top and bottom deck boards; an identity marking identifying an entity as associated with the pallet; pallet condition attributes, including one or more indicators of: twisted block; missing block; cracked block; waning block; broken deck board; missing deck board; cracked deck board; waning deck board; missing or covered labelling; discolored wood; waning block; foreign substance on deck boards; and protruding nail. Assigning the pallet evaluation metric for each pallet comprises: assigning the pallet to a pallet category based on the pallet configuration attributes indicated for the pallet in the inspection data; assigning an initial pallet evaluation to the pallet based on the assigned pallet category; mapping the pallet condition attributes indicated for the pallet in the inspection data to repair operations required to fix the pallet condition attributes; adjusting the initial pallet evaluation based on the required repair operations; and determining the pallet evaluation metric based on the adjusted initial pallet evaluation.

[0019] In some examples, the inspection data for each pallet includes one or more images of the pallet indicating locations of any regions that correspond to one or more of the pallet condition parameters.

[0020] According to one or more of the preceding examples, the method includes: determining, using the automated system, a processing plan for each pallet based on one or both of the inspection data or pallet evaluation metric of the pallet, the processing plan specifying one of scrap, repair or no-work required processing; and sending, using the automated system, the processing plan to a controller of an automated pallet routing and repair system for implementation.

[0021] According to one or more of the preceding examples, the method includes: obtaining, at the automated system, pallet evaluation metric data representing current pallet evaluation metrics in one or more geographic regions, wherein assigning the pallet evaluation metric for each pallet is further based on the pallet evaluation metric data.

[0022] According to one or more of the preceding examples, the method includes: determining, using the automated system, a routing option within a pallet processing facility for each of the pallets in the pallet batch based at least in part on the inspection data for each pallet, wherein the routing options can include options that will divert the pallet from re-entry into a pallet ecosystem; maintaining, using the automated system, historic data that includes pallet configuration attributes as identified in the respective inspection data obtained for the pallets of multiple historic pallet batches, well as a routing data indicating the respective routing options determined for the pallets of multiple historic pallet batches; mining, using the automated system, the historic data to identify groups of pallets that have respective routing data indicating that the pallets were diverted from re-entry into the pallet ecosystem; detecting, using the automated system, any identified groupsof pallets that meet a defined pallet number threshold; and generating, using the automated system, an electronic notification indicating any detected identified groups. The electronic notification triggers an analysis as to whether the detected identified groups can be re-introduced into the pallet ecosystem.

[0023] According to a second aspect, a pallet processing automated management system is disclosed that includes one or more processors and electronic storage storing instructions that, when executed by the one or more processors, cause the pallet processing automated management system to implement the automated system and perform the method of any one of the preceding methods.

[0024] According to a further example aspect, an automated pallet processing facility, is disclosed that includes an incoming pallet handling system for receiving an incoming batch of pallets; an automated pallet inspection machine coupled to the pallet handling system to receive the pallets, the automated pallet inspection machine being configured to generate digital inspection data for the pallets based on an automated visual inspection of the pallets, the digital inspection data for each pallet including (i) configuration attributes for the pallet indicate at least a length and width of the pallet and (ii) one or more condition attributes for the pallet that indicate any defects detected according to a predefined list of possible defects; and an automated pallet routing system configured to receive the pallets from the automated pallet inspection machine and selectively route the pallets to one of multiple possible downstream processing paths. An automated management system coupled to communicate with the automated pallet inspection machine and receive the digital inspection data for the pallets, the automated management system being configured to: assign a respective pallet category from a set of predefined pallet categories to each pallet, based on the configuration attributes for the pallet. The automated management system is also configured to,for at last some of the pallets, assign a pallet evaluation metric to each pallet based on: (i) a current market evaluation metric for the respective pallet category assigned to the pallet; and (ii) a current market evaluation metric for any repairs required to correct any defects indicated in the condition attributes for the pallet; and select, from the multiple possible downstream processing paths, a downstream processing path for each pallet based on the pallet evaluation metric assigned to the patent; and for each pallet, send a signal to the automated pallet routing system to cause the pallet to be routed to the downstream processing path selected for the pallet.

[0025] In some examples, the automated management system is configured to periodically automatically update the current market evaluation metric for each of the pallet categories based on a tracked database of selling values for a preceding duration for pallets belonging to each of the pallet categories.

[0026] In some examples, the multiple possible downstream processing paths consist of: (i) a repair processing path; (ii) a pallet sorting path for pallets that are to be to be shipped as usable pallets; and (iii) a diversion path that diverts the pallet from the repair processing path and the pallet sorting path. The predefined pallet categories each have an associated set of specified configuration attributes, and the automated management system is configured to: assign the respective pallet category to each pallet based on identifying a match between the configuration attributes of the pallet and the set of specified configuration attributes associated with the pallet category, wherein when a match cannot be identified, a pallet category defined for pallets that cannot be matched is assigned to the pallet; and for each pallet assigned to the pallet category defined for pallets that cannot be matched, send a signal to the automated pallet routing system to cause the pallet to be routed to the diversion path.

[0027] In some examples of the automated pallet processing facility, the pallets for which the pallet evaluation metric is assigned are pallets that have been assigned respective pallet categories that are not the pallet category defined for pallets that cannot be matched, and the automated management system is configured to, for each pallet for which the pallet evaluation metric is assigned: (i) select the repair processing path for the pallet when the condition attributes for the pallet indicate a repair is required and the pallet evaluation metric meets a defined threshold; (ii) select the pallet sorting path for the pallet when the condition attributes for the pallet indicate no repairs are required and the pallet evaluation metric meets the defined threshold; and (iii) select the diversion path for the pallet when the pallet evaluation metric falls below the defined threshold.

[0028] In some examples, the automated management system is configured to assign a batch evaluation metric for the batch of pallets based on a sum of the pallet evaluation metrics assigned to the pallets individually in the batch of pallets.

[0029] In some examples, the configuration attributes includes a unique treatment facility identifier associated with a treatment code, wherein the current market evaluation metric for at least some of the respective pallet categories is based at least in part with a category specific unique treatment facility identifier associated with the respective pallet category.

[0030] According to a further aspect, an automated pallet deposit and compensation system is disclosed that includes: an automated pallet inspection machine for generating inspection data for respective pallets; an automated incoming pallet handling system configured to receive an incoming batch of pallets and automatically feed the incoming pallets to the automated pallet inspection machine; an automated system configured for (i) obtaining the inspection datafrom the automated pallet inspection machine for each pallet in the batch of pallets from the automated pallet inspection machine, (ii) assigning a pallet evaluation metric for each pallet based on the inspection data obtained for the pallet, (iii) assigning a batch evaluation metric for the batch of pallets based on the pallet evaluation metrics assigned to each pallet in the batch of pallets, and (iv) determining a compensation amount based on the batch evaluation metric and causing the compensation amount to be credited to a supplier of the batch of pallets.BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of the present application, and in which :

[0032] FIG. 1A is a perspective view illustrating a common stringer pallet configuration.

[0033] FIG. IB is a perspective view illustrating a common block pallet configuration.

[0034] FIG. 2 illustrates a representation of a treatment code stamp or label that can be applied to a pallet.

[0035] FIG. 3 is a schematic diagram illustrating a pallet ecosystem.

[0036] FIG. 4 is a top-level block diagram of a pallet processing facility that includes an automated management system according to example aspects of the present disclosure.

[0037] FIG. 5 is a block diagram shows a set of operations that can be performed by the automated management system of FIG. 4 to obtain market data that can then be used to reduce a quantity of pallets that are diverted from a pallet ecosystem, according to example implementations.

[0038] FIG. 6 is a chart illustrating a defined list of pallet categories and their respective set of configuration attributes.

[0039] FIG. 7 is chart illustrating pallet selling prices by category code.

[0040] FIG. 8 is a block diagram of a computing system that can be used to implement one or more aspects of the present disclosure.

[0041] Similar reference numerals may have been used in different figures to denote similar components.DESCRIPTION OF EXAMPLE EMBODIMENTS

[0042] An example of a pallet reuse ecosystem in which examples of the systems and methods described in this disclosure may be applied is illustrated in FIG. 3. In the example of FIG. 3, pallet users, for example, customers 302 receive shipments of new and / or used pallets (also known as load platforms). Used pallets can, for example, come from a pallet processing facility 300. New pallets can, for example come from an original pallet source 308 that manufactures new pallets. In some cases, a pallet customer 302 and original pallet sources 308 can be the same entity. In some cases, pallet customers 302 can be pallet resellers who resell pallets to other customers who are the actual users of the pallets. The pallets are then used as platforms for supporting goods and pass through one or more shipping channels 304 before arriving at their ultimate destinations where they are unloaded. At thatpoint, the empty pallets may either be introduced back into the pallet reuse ecosystem or diverted from the shipping industry as waste or for other uses. In the illustrated example, pallets that are reintroduced into the pallet reuse ecosystem can be obtained from any number of used pallet suppliers 306 for processing at a used pallet processing facility 300.

[0043] In the illustrated ecosystem, there will typically be many independently controlled used pallet suppliers 306, each of which may have used pallets at one or more geographic locations. Potential used suppliers 306 can include any entity that ends up in possession of used pallets, such as but not limited to: warehouses; distribution centers; retail stores; construction sites; restaurants; manufacturing plants; food processing plants; and military and other institutional facilities that receive and consume bulk shipments of goods.

[0044] Used pallets can have multiple different sizes and configurations and be in different states of usability following their respective paths through diverse shipping channels 304 and shipping conditions.

[0045] As a result of the diverse sources of used pallets and the variations in the size, configuration and conditions of used pallets, collection and processing of such pallets gives rise to many logistical and other challenges that must be overcome to optimize pallet reuse and prevent unnecessary and wasteful diversion of pallets from the pallet reuse ecosystem. Example solutions are presented in this disclosure of a pallet processing systems and methods that can applied in the context of a used pallet processing facility 300 to optimize the pallet reuse ecosystem. Among other things, the disclosed solutions can reduce a number of used pallets that end up being discarded.

[0046] In this regard, FIG. 4 shows a block diagram of an example of used pallet processing facility 300, according to example aspects of the disclosure. Used pallets 402 are received at pallet processing facility 300 in pallet batches 401 for inspection, repair if necessary, and sorting before the pallets are provided to pallet customers 302. In Figure 4, solid lines are used to illustrate physical pallet transport systems (e.g., conveyors and other pallet transport platforms) located at the pallet processing facility, and dashed lines are used to illustrate data flow between computing components, which may for example be connected via wired and / or wireless communication networks. The pallet processing facility 300 includes the following components, each of which will be described in greater detail below: an in-feed handling system 404 for receiving incoming pallet batches 401; an automated inspection system 408 for inspecting pallets 402; a routing and repair system 450 for processing inspected pallets; and an automated management system 416.

[0047] Automated management system 416, which can for example be implemented using one or more suitably configured computing systems (for example one or more enterprise servers), is provided to manage various automated systems of the processing facility 300 as well as interactions with pallet suppliers 306 and customers 302. The functionality of automated management system 416 may be performed on a single computing device or may be distributed among multiple devices. Such computing devices may be co-located at the same physical site as the physical pallet handling equipment of pallet processing facility 300, or may be cloud-based computing devices, or a combination of site-located and cloudbased devices. In some examples, automated management system 416 is a component of an enterprise resource planning (ER.P) system that is associated with one or more pallet processing facilities 300. In an example embodiment, automated management system 416 includes an internal user interface module 472 that provides a human-machine interface between the automated management system416 and one or more authorized users associated with processing facility 300. User interface module 472 can enable an authorized user to access, view, and edit data and control commands that support the functioning of automated management system 416.

[0048] In an example implementation, automated management system 416 is configured to maintain or access one or more databases that provide current market data 434 in respect of the pallet market. Market data 434 can include, for example, for each pallet size and configuration combination, one or more of the following market data attributes: (i) going market selling rate (i.e., what customers are willing to purchase used pallets for); (ii) going market acquisition rates for a pallet processing facility 300 to acquire used pallets (i.e., amount of compensation that suppliers are willing to supply used pallets for - in many cases this amount may be zero or even negative as suppliers may be willing to give away pallets or pay for their removal to avoid disposal costs); (iii) repair cost data for different categories of repairs; (iv) tear down value of pallet components; (v) current transport costs such as pick-up costs per distance travelled for picking up used pallets; (vi) delivery costs per distance travelled for delivering used pallets; and (vii) recoverable carbon credit data for returning a pallet to service. In some examples, the market data parameters can be provided for different geographic locations and for different currencies. In some examples, values and costs may be expressed as standardized pallet units or credits, rather than, or in addition to, a country currency value. In some examples, automated management system 416 is configured to also maintain a database of customer data 470 about specific customers and / or potential customers. For example, customer data 470 could include information that identifies past or prospective customers, and one or more of the following for each of those customers: pallet delivery location; pallet preferences (e.g., configuration and grade); identity markings associated with the customer; and historic data for all past transactions with the customer, includingnumbers of pallets according to pallet configuration, pallet prices, dates, times and delivery locations. Regarding identity markings, pallets can, in some scenarios, include visible markings that can identify an entity that is associated with the pallet (e.g., a manufacturer or current user of that particular pallet configuration). By way of example, treatment codes, organizational stamps and certain pallet colors may be visible markings that associate an entity with a pallet. These markings thus provide a pallet attribute that can be used to link a particular pallet to a prospective customer.

[0049] By way of illustrative example, FIG. 5 shows an example of a set of set of market data operations 502 for obtaining and updating the market data 434. The market data operations 502 can be part of an automated software-driven process performed by an automated management system 416 to reduce the number of pallets that are diverted from a pallet ecosystem, according to example implementations.

[0050] As noted above, pallets come in many sizes and configurations that can determine the value and routing of the pallets, and market data 434 can include a set of market data for a number of possible pallet size and configuration combinations. In this regard, market data 434 includes a list 504 of predefined pallet categories. Each pallet category has a unique set of size and configuration attribute specifications. These pallet categories, which can each be indexed by a respective category code, can also be referred to as pallet recipes. In some examples, a pallet processing facility 300 may be expected to dozens or more types of predefined pallet categories. Accordingly, one of the operations (operation 503) of market data operations 502 is to obtain and maintain the list 504 of predefined pallet categories and the attribute specifications for those categories. The list 504 of pallet categories can be inclusive of pallets that have been identified as having a commercial value.

[0051] An example of partial list 504 of pallet categories is illustrated in FIG. 6, which include a set of category codes that are each associated with a unique set of attribute specifications that define a respective pallet "recipe".

[0052] The operation 503 of maintaining the pallet category list 504 can, in some examples be facilitated by human interaction via a suitable graphical user interface and input mechanism as supported by internal user interface module 472 (represented as Human Machine Interface (HMI) initiated update function 506 in FIG. 500). The pallet category list 504 can be periodically updated and maintained as information about new pallet categories or changes in the recipes associated with existing pallet categories become known.

[0053] In at least some example implementations, in addition to reacting to user inputs, the operation 503 can be configured to periodically automatically execute a function for identifying potentially new pallet categories (represented as automated data mining initiated update function 508 in FIG. 500). By way of example, as described above, automated management system 416 can generate processing plans for each pallet that, among other things, if a pallet should be scrapped or diverted for other processing (e.g., routed for teardown or shredding). In some at least some examples, the reason for a decision to scrap or divert a pallet can be because the pallet does not match with one of the saleable pallet categories that are included in pallet category list 504. Over time, historic batch data (e.g., batch records 444, described in greater detail below) that is maintained by automated management system 416 will build up data that identifies pallets that have been scrapped or diverted, and the pallet inspection data 414 for such pallets. In this regard, automated mining driven updates function 508 for identifying potentially new pallet categories can include the following automated steps: (i) parse the historic batch records 444 generated by the automated management system 416 to identify pallets that have been scrapped or diverted within a definedtime period for reasons other than the condition of the pallet itself, for example, because the pallet configuration does not match with any configurations included in the current pallet category list 504; (ii) apply one or more pattern recognition / clustering algorithms to cluster the identified pallets according to predefined groups of one more attributes; and (iii) generate a report that identifies pallet groupings that exceed a threshold size. By way of example, in step (i) a quantity of pallets (e.g., 10,000 pallets) are identified as having been scrapped or diverted within a defined time-period (e.g., a preceding month) for the reason that the pallets did not have configuration attributes matching a predefined pallet category; in step (ii) the identified pallets are clustered in groups according to similarity criteria ( by example, similarity criteria can be based on a defined set of one or more pallet attributes (e.g., length and width); (iii) in step three, the results of step (ii) are analyzed to identify any groups that exceed defined thresholds. For example, a group exceeding 1500 pallets may be identified as having length and width dimensions as falling within a defined threshold distance (e.g.,1 / 4 inch) of 31 inches by 47 inches. This information is included in a report generated for review by an authorized user, who can then determine if there is a market for such pallets. For example, the authorized user may conclude that 31 inch by 47 inch pallets correspond to European style 800mm by 1200mm pallets and that there is a viable local market for such pallets. In such a case, the authorized user can, via user interface module 472, cause the generation of one or more new corresponding category entries in the list of pallet categories 504 to ensure that such pallets will not automatically by scrapped or diverted in the future, but rather will be kept in the pallet ecosystem. In at least some examples, the automated management system 416 could also be configured to perform to automatically perform step (iii) - for example, automated management system 416 could be configured to generate a prompt for a generative Al model for any identified pallet groups such as "is there a market in Ontario for pallets with the dimensions of 31 inches by 47 inches".Based on the answer, automated management system 416 could cause a new category to be added to the list of pallet categories 504.

[0054] In some examples, a pallet attribute that is used in step (ii) for identifying a group of similar pallets for a possible new pallet category can be a visible identity marking (e.g., the unique identifier that is found in treatment codes or an organization's stamp, or a pallet color that is proprietary to an organization). If a threshold number of usable pallets that are identified as not belonging to any particular category are associated with a common unique identity making (e.g., heat treatment facility identifier) that pallet group can be flagged and the identifying marking used to identify a possible customer (e.g., the unique heat treatment facility identifier used to identify the operator of that treatment facility as a possible customer for those pallets). Based on linking the identity marking to an entity, a new pallet category code and associated attribute entry can be created for future use. For example, if a treatment facility operator is identified as a future customer based on a heat treatment code, then a new pallet category can be added to the list of pallet categories 504 based on the heat treatment facility identifier attribute; in some scenarios, multiple pallet categories could be created if there are multiple pallet configurations associated with the heat treatment facility identifier.

[0055] As noted above, market data 434 can also include a number of market data attributes that are used to assign a pallet evaluation metric to incoming pallets. In this regard, the set of market data operations 502 can also include a market condition tracking operation 510 that is configured to track and set respective pallet valuation metrics (e.g., market selling prices 512) for pallets in each pallet category code included in the pallet category list; current shipping costs 514; and current repair costs per repair type. In some examples, shipping costs and repair costs can be uniquely assigned per pallet category code - for examplethe cost for a specific repair type for one pallet category code can be different than the cost for the same repair type for a different pallet category code.

[0056] By way of example, market selling prices 512 per pallet category code can be automatically updated at periodic intervals (e.g., daily, weekly, or monthly) based on an average of data collected for sales made by the pallet processing facility 300 over a preceding threshold number of units sold or for a defined sales period (e.g., average price for the last 5000 pallets for a specific pallet category code, or average price for pallets for a specific pallet category code sold over the last seven days) or a combination thereof. Current shipping costs 514 (e.g., cost per distance travelled, as obtained from a fleet management system) and current repair costs per repair type 516 can be automatically updated in a similar manner. In at least some examples, a human can be included in the loop to periodically audit, verify and / or approve the automatically generated values.

[0057] By way of example, FIG. 7 shows an example of pallet category selling price 512 as tracked by current market condition tracking operation 510.

[0058] Referring again to FIG. 4, automated management system 416 is configured interact with used pallet suppliers 306 to gather information about potential pallet batch 401 pickups, evaluate the potential pallet batch 401 pickups and schedule such pickups. In this regard, in an example implementation, automated management system 416 is configured to maintain or access one or more databases that provide current supplier data 432 for a plurality of different suppliers 306 that are registered with the automated management system 416. By way of example, the supplier data 432 can include, for each supplier 306, some or more of the following attributes: (i) supplier ID; (ii) supplier name; (iii) supplieraddress; (iv) supplier contact details (e.g., email); (v) supplier payment information (e.g., e-transfer details); (v) historic data about past interactions with supplier, such as batch data (including batch evaluation metrics) obtained in respect of previous pallet batches 401 received from the supplier, and previous pick-up locations and dates; (vi) supplier evaluation metric data providing an evaluation of the supplier; (v) a suggested pick-up frequency as computed by automated management system 416 based on historic information for the supplier; (vi) suggested next pick up date.

[0059] In an example embodiment, automated management system 416 is configured to implement an external user interface module 436 that provides or interacts with a web-based interface that supports intake of a pallet batch 401 from a supplier 306. For example, the web-based interface can include interactive fields that enable a supplier 306 to provide new batch data indicating that a batch of used pallets is available. Such new batch data can, for example, indicate at least some of the following attributes: Supplier ID; a pickup request and the geographic location and desired time for the pickup (if batch is to be picked up from a remote location); an estimated drop off time (of batch is to be delivered to the Pallet Processing Facility 300 site; an estimated number of pallets; and potentially other data such as pallet configurations, sizes and conditions. In some examples, a link to the webbased interface is included in an email or text that is periodically automatically generated and sent to an email address or text number associated with the pallet supplier 306 (e.g., an email address or text number stored as part of supplier data 432).

[0060] By way of example, in one scenario, automated management system 416 is automatically configured to cause external user interface module 436 to proactively send electronic messages (e.g., texts or emails) to electronic addresses associated with used pallet suppliers 306 that are tracked in supplierdata 432. For example, as indicated above, data for a supplier can include a suggested pick-up frequency as computed by automated management system 416 based on historic information for the supplier. This pickup-up frequency may, for example be determines as follows. Automated management system 416 can include a prediction tool that parses the historic data about past pallet batches acquired from supplier to predict, based on historic trends, when that supplier should have a commercially viable load of pallets available for pickup. Among other things, the prediction tool may suggest a pickup frequency for a supplier (e.g., every 1 month, 3 month, 2 weeks, etc.). In at least some examples, the prediction tool can cluster multiple suppliers from a geographic region and predict a pickup frequency for a group of suppliers based on historic pallet batch data for the geographic region. The Automated management system 416 can be configured to compare the predicted pick-up frequency duration with a last known pick-up date, and use that information to cause external user interface module 436 to proactively send pick-up inquiry messages (e.g., texts or emails) to electronic addresses associated with used pallet suppliers 306.

[0061] By way of example, an auto-generated pick-up message sent as a text message to a phone number associated with a supplier could state "This is ABC Pallet Co. Do you have Pallets ready for pickup at site location 123 Any Street, Anytown ?. If so, send reply text with estimated number. If address is incorrect, please text correct address". Upon receiving notification from a supplier via the external user interface module 436 of a new batch (e.g., via a web interface or a response to a text or email message), automated management system 416 assigns a unique Batch ID, associated with an supplier ID for the supplier, and starts tracking batch data for the Batch ID. In the text message example noted above, the external user interface module 436 can parse the return text message from a supplier to identify and extract new batch data (e.g., the estimated quantity) andany updated address information that may be in the message, and associate that information with the supplier data 432 based on the text number of the supplier.

[0062] In some examples, upon receiving indication of a prospective new pallet batch, automated management system 416 is automatically configured to perform an evaluation in respect of the new batch to determine if the new batch should be accepted or rejected, as well as an optimized pickup scheduling that enables batches from multiple locations to be efficiently collected. This evaluation can, for example, apply a new batch evaluation module 438 (which may, for example, comprise one or more deterministic rule-based models, machine learning based models, or a combination of both) to map a set of input attributes obtained from the supplier data 432, the new batch data, and market data 343 to one or more indicators of: (i) an estimated new batch value or score; (ii) if the new batch should be accepted or rejected; (iii) an optimized pick up scheduling (e.g., assignment of a pickup vehicle and time that enables efficient pickup of multiple batches from multiple locations within a geographic region).

[0063] By way of example, the number of pallets in a batch, geographic location of the batch, current pallet market prices (selling and buying), current transport cost (e.g., shipping) data, current carbon credit data, and the historic supplier evaluation metric data, together with information about other possible batch pickups in a common geographic region, can all be provided to new batch evaluation module 438 that classifies the new batch as feasible (accepted) or not feasible (rejected), assigns a new batch value that corresponds to a potential compensation payment or credit for the supplier 306, and generates a pick-up schedule. This information can all be added to the new batch data that is associated with the previously assigned unique Batch ID and stored as part of supplier data 432. In an example implementation, the new batch evaluation module 438 calculates an anticipated pick-up shipping cost for the batch based on the numberof pallets (which determines required shipping volume), geographic location of the supplier and the tracked shipping costs data 514. The pick-up shipping cost can be stored as part of the new batch data.

[0064] In examples, all or some of the information generated by new batch evaluation module 438 can be fed back to supplier 306 via the external user interface module 436 to advise the supplier 306 whether the pallet batch has been accepted or rejected, a potential value of the batch, and an estimated pick-up time (which can be a time window in some examples).

[0065] In example embodiments, the automated management system 416 is further configured to generate pick-up instructions to dispatch vehicles to pick up new batches that have been accepted. The pick-up instructions can include the Batch ID for each batch, together with pick up an optimized pick-up schedule that includes vehicle assignments, geographic locations and pickup times. In some examples, the automated management system 416 includes a shipping optimization module that applies known shipping optimization strategies to optimize vehicle loading, vehicle routing and tracking of shipping expenses that can be then used as source data for shipping costs data 514 for future pallet batch valuations. Delivery and routing instructions can be provided to drivers' respective mobile terminals (e.g., driver communication devices such as smartphones or dedicated mobile terminal equipped with SAT NAV systems). The driver mobile terminals are configured to exchange electronic information with automated management system 416 to provide drivers with pick up instructions and routing information and enable real-time feedback from driver mobile terminals to the automated management system 416.

[0066] In an example embodiment, at the time of pick-up, the pallets that are associated with a new batch are associated with a physical indicator of thepreviously assigned Batch ID. For example, a physical quick-response (QR) label (barcode or 2-D matrix) or RFID tag or other physical marker that indicates the Batch ID is physically attached (e.g., by plastic wrap or staples) to one or more pallets of the new batch, and the pallets of the new batch are physically organized into an identifiable pallet batch 401 (e.g., as a stack or stacks that are part of a vehicle load, or as an entire vehicle load). In some scenarios, a mobile printer can be integrated with a mobile terminal that is provided to pick-up vehicle driver that enable the driver to print a physical QR labels at the pick-up location for affixing to a pallet batch.

[0067] In example implementations, drivers will count the pallets on-site at the pickup location and input this information into the mobile terminal for transmission to automated management system 416. In at least one example embodiment, the driver mobile terminal is equipped with camera for capturing an image of the pallet batch, and an object detection and counting application that identifies pallets in the captured image and counts them. In some examples, the object detection and counting application can be configured to perform a preliminary pallet category classification to identify numbers of each of the different pallet categories. This preliminary batch pallet count (total count, and in some examples, per category count), and in some examples, the captured image(s), can be transmitted back to automated management system 416 in real-time. In some examples, the automated management system 416 Such information, which will provide both quantity information, as well as a current location of the pick-up vehicle, may be used by the shipping optimization module to determine if real-time modifications can be made to a pick-up run schedule (e.g., add more stops if pickup vehicle load will be less than expected or reschedule later pickups if pick-up vehicle load is greater than expected) in order to optimize pallet batch pick-up as it is occurring. The pick-up site estimated total quantity (and, in some cases, category specific quantity information) can be stored as part of the new batch data byautomated management system 416 in association with the previously assigned unique Batch ID, and stored as part of supplier data 432.

[0068] In some examples where a pallet batch is provided directly to the pallet processing facility 300 by a supplier, a physical supplier interface (for example a user terminal) can be provided at the pallet processing facility 300 to facilitate the new batch intake functions described above, including generating of a new Batch ID and new batch data.

[0069] Accordingly, in the illustrated example, used pallets 402 are received in batches 401 at pallet processing facility, with each pallet batch 401 being associated with a respective Batch ID that has been previously assigned. Pallet processing facility includes a Batch ID input system 406 for acquiring the Batch ID that has been previously assigned to the incoming pallet batch 401. In example embodiments, the Batch ID input system 406 can include an input interface such as a QR reader, RFID scanner, keyboard or other input means enabling reading or input of the Batch ID associated with the incoming pallet batch 401. The Batch ID can, for example, be communicated to a batch tracker module 442 of the automated management system 416 that is configured to track batch data in respect of each pallet batch 401 as the batch proceeds through pallet processing facility 300. In example embodiments, the batch tracker module 442 begins populating a pallet batch record 444 upon receiving a Batch ID that has been obtained via the incoming batch ID input system 406. In some examples, the batch tracker module 442 uses the Batch ID to retrieve information (e.g., supplier data, estimated number of pallets in batch, and any known size, configuration information for the pallets) from the new batch data that has been previously stored in connection with that Batch ID as part of the supplier data 432, and adds that information (or pointers to that information) in the pallet batch record 444. In some examples, batch tracker 442 can be configured to create and start tracking abatch record 444 earlier in the process than when the batch is physically received - for example, as soon as a new batch record ID is assigned to a prospective pallet batch based on a communication with a pallet supplier.

[0070] Each incoming pallet batch 401 is provided to in-feed handling system 404. For example, pallets 402 in a pallet batch 401 may be unloaded from an incoming vehicle such as a truck by a forklift placed on a receiving structure of the in-feed handling system 404. In example embodiments, in-feed handling system 404 can include automated pallet transporting components such as one or more conveyors, an accumulator, and a tip-feeder that are configured to organize and feed a steady stream of spaced apart pallets 402 individually to the automated inspection system 408.

[0071] In-feed handling system 405, automated inspection system 408, and routing and repair system 450 can each include detectors (illustrated by boxes labelled "D" in Figure 4) for determining the position of pallets 122 as they move through the in-feed handling system 405, and this tracking information can be fed in real-time to the batch tracker module 442 of automated management system 416. As part of the pallet batch record 444, batch tracker module 442 is configured to maintain a respective data package for each pallet 402 included in the pallet batch 401. The detectors D are positioned to collect tracking data that enables the batch tracker module 442 to individually assign a pallet ID to each incoming pallet 402 in a batch 401 and track the location of that pallet 402 as it progresses through the pallet processing facility 300. The detectors D may include photoelectric sensors, photo-eyes, and / or computer vision-based detection systems, for example.

[0072] Pallets 402 are individually inspected at the automated inspection system 408. In the illustrated example, automated inspection system 408 includes a sensing system 410 that comprises multiple sensors for visually inspecting pallets402. Data from the sensors are provided to a sensor data processing system 412 that generates multiple inspection parameters (pallet inspection data 414) for each pallet 402 based on data received from sensing system 410.

[0073] In at least some example embodiments, the sensor data processing system 412 comprises multiple rules-based and / or machine learning based models that have been configured to predict parameters for respective attributes of the pallet. The pallet attributes can for example include size attributes, configuration attributes and condition attributes. Size attributes can, for example, include: length, width, and height. Configuration attributes can, for example, include: block, stringer, number of bottom deck boards; number of top deck boards; deck board spacing; deck board pattern; color; material. Condition attributes can, for example, include: twisted block; missing block; cracked block; waning block; broken deck board; missing deck board; cracked deck board; waning deck board; missing or covered labelling; discolored wood; waning block; foreign substance (e.g., fungi, paint, mold) on deck boards; and protruding nail. In some examples, the configuration pallet attributes can also include treatment code, which can be scanned and associated with the subject pallet. In some examples, condition pallet attributes can also include an overall pallet grade, for example "Grade A" could be associated with a pallet that is in excellent condition and appears suitable for display on a retail floor; and "Grade B" could denote a pallet that is structurally solid and suitable for use in a supply chain, but have visible indications of previous repairs. In this regard, sensor data processing system 412 can comprise a rules- based and / or machine learning based model that classifies pallets by grades.

[0074] By way of non-limiting example, automated inspection system 408 can be implemented using the PALLETAI™ pallet inspection system available from IVISYS INC, which uses lasers and color and black and white vision systems in combination with multiple neural networks to predict multiple pallet attributes.

[0075] In example embodiments, pallet inspection data 414 that is generated by automated inspection system 408 will include the pallet attributes as well as associated images in which indicators of at least some of the predicted attributes are visibly overlaid onto a representation of the pallet.

[0076] The pallet inspection data 414 generated for each pallet 402 is assembled into a pallet inspection data package, together with the Batch ID and in some cases, a Pallet ID, and provided in real-time to the automated management system 416, which can add the pallet inspection data 414 to a pallet record that is being maintained in association with the Pallet ID as part of the batch record 444. The pallet ID can, for example, be assigned based on an inspection order of the pallets within a batch.

[0077] Automated management system 416 can include a pallet analyzer module 440 is configured to generate one or more outputs in respect of a pallet 402 based on the pallet inspection data 414 that is received from the automated inspection system 408, as well as market data 434. By way of example, market data 434 could include attributes noted above, namely current pallet market prices (selling and buying), current carbon credit data, and repair costs for different types of repairs (including the types of repairs required to address the above-noted Condition attributes). Pallet analyzer module 440 can, for example, include rules- based and / or machine learning based models that have been configured to map attributes obtained from the pallet inspection data 414 and market data 343 to one or more indicators of: (i) an estimated pallet evaluation metric (e.g., a pallet value or score); (ii) a pallet processing plan indicating how the pallet 402 is to be processed by routing and repair system 450. Among other things, the pallet processing plan can indicate if the pallet should be scrapped, repaired, left as-is, or diverted for other processing (which in example embodiments may be based oncomparison of the pallet evaluation metric to a defined threshold); and repair instructions for pallets that are to be repaired.

[0078] In an example implementation, pallet analyzer module 440 is configured to perform the functions described in the previous paragraph by first assigning each pallet 402 included in the batch to a respective one of the pallet categories that are included in the pallet categories list 504. Pallets that cannot be assigned to a particular pallet category can be designated with an "unmatched" category code that indicates that the pallet can't be matched to a pallet category in the current pallet categories list 504. In example implementations, the pallet analyzer module 440 includes a pallet category classification function to assign pallet categories. This function can, for example, include on or more rules-based and / or machine learning based algorithms or models that match individual pallets to a pallet category code based on a comparison of the pallet attributes that are included in the pallet inspection data 414 for a pallet to the configuration attributes specified in the pallet categories list 504. By way of example, attribute vectors can be determined for each pallet and each pallet category within a multi-dimensional "pallet attribute space", with pallet category matches for a pallet being determined based the attribute vector for that pallet being within a defined threshold distance of an attribute vector for a specific pallet category. Pallets that have attribute vectors that don't fall within a threshold distance of any predefined pallet category attribute vectors can be assigned to the pallet category reserved for "unmatched" pallets.

[0079] The pallet category that is assigned to a pallet can then be used by pallet analyzer module 440 to assign a preliminary pallet evaluation metric for the pallet 402 that can, for example, be (or be based on) the preliminary pallet evaluation metric that is currently set for the pallet category in the market data 434(e.g., the current pallet selling price as included in the stored list 512 of pallet selling prices by category code).

[0080] The pallet analyzer module 440 can also determine a preliminary pallet processing plan for the pallet 402 by mapping the pallet condition attributes that are included in the inspection data 414 to required repair operations using one or more rules-based and / or machine learning based algorithms. Based on the repair costs 516 stored as market data, the pallet analyzer module 440 can assign a repair cost metric to the pallet 402, and this value can then be subtracted from the preliminary pallet evaluation metric for the pallet 402 to provide an adjusted pallet evaluation metric. In some examples, this adjusted pallet evaluation metric can then be used to determine if the pallet 402 should be routed out of the pallet processing chain (e.g., tear down / scrapping or alternative processing), or kept with the pallet processing chain (e.g., routed for repair or to resale processing operations such as sorting).

[0081] In example implementations, the output analysis data generated by pallet analyzer 440 is added to the pallet record for the subject pallet 402, and the pallet processing plan is further provided to an automated systems controller 430 of the routing and repair system 450 (discussed in greater detail below).

[0082] Once the pallets 402 associated with an incoming pallet batch 401 have been inspected by automated inspection system 408 and added to the batch record, a final batch evaluation can be performed, for example by a final batch evaluation module 446. Among other things, a final batch evaluation metric can be determined based on the individual pallet evaluation metrics estimated for each of the pallets 402 included in the incoming pallet batch 401. By way of example, a final batch evaluation metric can be based on summing the previously determined pallet evaluation metrics (as adjusted for any applicable repair costs) for the pallets402, and subtracting an incoming shipping cost for the pallet batch (e.g., the pickup shipping cost that was previously calculated as part of new batch data).

[0083] Furthermore, the previously mentioned supplier evaluation metric for the supplier of the batch 401 can be updated based on the final batch evaluation metric, and the supplier data 432 updated accordingly.

[0084] In some examples, once the final batch evaluation metric is determined for pallet batch 401, the automated management system 416 sends an electronic notice to the supplier of the pallet batch 401 indicating the final batch evaluation metric and / or a payment amount for the supplier based on the final batch evaluation metric. For example, the payment to the supplier could be based on a percentage of the final batch evaluation metric. In some examples, automated management system 416 also triggers an electronic funds or credit transfer for the benefit of the supplier. Such a transfer could for example take the form of an e- transfer to an electronic address associated with the supplier or a wire transfer to a bank account associated with the supplier in supplier data 432.

[0085] Inspected pallets 402 are fed individually from the automated inspection system 408 to the routing and repair system 450. The routing and repair system 450 includes a plurality of transport and processing subsystems that are collectively controlled by automated systems controller 430 in order to process inspected pallets 402 in accordance with their respective pallet processing plans. In one example, a pallet routing system 418 is controlled, based on the pallet processing plan for a subject pallet, to direct the pallet to one of (i) an automated tear down station 420; (ii) a repair line that includes one or more repair stations 426; (iii) an automated sorting system 428; or (iv) alternative processing (other).

[0086] Pallets that are directed to tear down station 420 can be dissembled by one or more an automated robots, with reusable components 422 automatically sorted and routed for reuse, and waste components being disposed of (e.g., via a chipper 424).

[0087] Pallets that are directed to the repair line can be directed to manual or automated repair stations 426, accompanied by with repair instructions that can be visually displayed or automatically implemented. Repaired pallets can then be routed to automated sorting system 428.

[0088] Pallets that require no repair can be routed straight to automated sorting system 428.

[0089] Pallets that are directed to alternative processing (other) may, for example, be provided to a manual unloading zone. Such pallets may for example include pallets that do not fit into one of the sorting categories of automated sorting system 428. This could for example include non-wooden pallets, pallets that are too badly damaged to move through the transport system, pallets that are known based on physical indicators to belong to a third party, and pallets that have unconventional sizes or configurations. Pallets that are identified during automated inspection as not belonging to a specific pallet category code may in some cases be routed to a manual unloading zone.

[0090] Automated sorting system 428 is configured to sort pallets 402 based on pallet configuration (e.g., based on the pallet category code previously assigned to each pallet) into stacks, enabling the pallets 402 to be subsequently loaded and shipped to customers 302.

[0091] Among other things, data collected by automated management system 416 enables the types of repairs being made to the pallets 402 to be tracked, such that statistical data can be collected including how many pallets are being repaired, how much time and lumber is being consumed or is expected to be consumed in repairing the pallets, as well as tracking what repairs are being made. By analyzing the types of repairs being made to the pallets for a particular supplier, certain trends may be noted. For example, a supplier may be damaging the supports blocks on the pallets more often than other suppliers, or the top deck boards are being replaced more often than other suppliers. This information can be used in in setting supplier evaluation metrics, and enabling more informed decisions to be made in estimating the valuing of new pallet batches.

[0092] As noted above, in some examples, automated management system 416 is configured to maintain a database of customer data 470 about specific customers and / or potential customers. For example, customer data 470 could include information that identifies past or prospective customers, and one or more of the following for each of those customers: pallet delivery location; pallet preferences (e.g., configuration and grade); treatment code(s) associated with the customer; and historic data for all past transactions with the customer, including numbers of pallets according to pallet configuration code, pallet prices, dates, times and delivery locations. In some examples, pallet data may be tracked for prospective customers based on treatment codes.

[0093] In this regard, the methods and system described system described above enables pallets to be identified and sorted for multiple customers - both generally and specifically. For example, pallet categories defined in the list 504 of pallet categories can be based on physical configuration attributes than can be meet the requirements of a number of known customers that are tracked in customer data 470. In an example implementation, automated managementsystem 416 is configured to maintain an inventory of pallets, indexed by pallet category code, that are currently available and predicted to be available within a defined future timeframe. In some example embodiments, automated management system 416 is configured to predict future requirements of customers based on historic order data (e.g., frequency of orders, pallet categories and quantities ordered, last order date) and based on those predictions, automatically send electronic messages (e.g., text, email, or client app notifications) to electronic contact information associated with specific customers to notify those customers of availability of pallets that correspond to pallet category codes that are tracked in the customer data 470 as being of interest to those specific customers.

[0094] In some examples, specific pallet category codes can be associated with specific customers in customer data. For example, as noted above treatment code data can be included as a pallet attribute for a specific pallet category code, thereby mapping that code to a specific customer. In some examples, customers will have a specific stamp or color or configuration that is considered proprietary to that customer, and in such cases a specific pallet category code can be set up for such customers. In some examples, category code classification on an incoming pallet can be performed on a hierarchical level - for example a first category code and a second category code included in list 504 could be associated with identical configuration attributes but for an attribute that indicates a specific customer (e.g. a treatment code or customer ID stamp or color attribute). An incoming pallet that meets all of the non-customer identifying attributes associated with both the first and second category codes but also includes a customer identity attribute will be preferentially assigned to the category that specifies the same customer identity attribute.

[0095] In some examples, at some point during processing of an incoming pallet, a certification attribute may be added to the pallet record that is beingtracked for that pallet to verify that processing facility certifies that the pallet meets certain criteria. A corresponding stamp can also be physically applied to the pallet, which can then be detected using optical sensing and be incorporated as an pallet configuration code attribute in future pallet inspections.

[0096] From the above description it will thus be appreciated that in some example embodiments, automated pallet processing facility 300 includes: an incoming pallet handling system 404 for receiving an incoming batch 401 of pallets 402, and an automated pallet inspection machine (system 408) coupled to the pallet handling system 404 to receive the pallets 402. The automated pallet inspection machine is configured to generate digital pallet inspection data 414 for the pallets 402 based on an automated visual inspection of the pallets 402 performed, the digital inspection data 414 for each pallet 402 including (i) configuration attributes for the pallet that indicate at least a length and width of the pallet and (ii) one or more condition attributes for the pallet 402 that indicate any defects detected according to a predefined list of possible defects.

[0097] The automated pallet routing system 418 is configured to receive the pallets 402 from the automated pallet inspection machine 408 and selectively route the pallets 402 to one of multiple possible downstream processing paths. Automated management system 416 is coupled to communicate with the automated pallet inspection machine 408 and receive the digital inspection data 414 for the pallets 402. The automated management system is configured to assign a respective pallet category from the list 504 of predefined pallet categories to each pallet 402, based on the configuration attributes for the pallet 402. The automated management system 416 is also configured to, for at last some of the pallets 402: (A) assign a pallet evaluation metric to each pallet based on: (i) a current market evaluation metric for the respective pallet category assigned to the pallet; and (ii) a current market evaluation metric for any repairs required to correct any defectsindicated in the condition attributes for the pallet; (B) select, from the multiple possible downstream processing paths, a downstream processing path for each pallet based on the pallet evaluation metric assigned to the patent; and (C) for each pallet, send a signal to the automated pallet routing system to cause the pallet to be routed to the downstream processing path selected for the pallet.

[0098] As noted above, the automated management system 416 can be configured to periodically automatically update the current market evaluation metric for each of the pallet categories based on a tracked database (e.g., market data 434, and / or customer data 470) of selling values for a preceding duration for pallets belonging to each of the pallet categories.

[0099] In some examples, the multiple possible downstream processing paths consist of: (i) a repair processing path; (ii) a pallet sorting path for pallets that are to be to be shipped as usable pallets; and (iii) one or more diversion paths (e.g., tear down, other) that diverts the pallet from the repair processing path and the pallet sorting path. The predefined pallet categories each have an associated set of specified configuration attributes, and the automated management system 416 is configured to: assign the respective pallet category to each pallet based on identifying a match between the configuration attributes of the pallet and the set of specified configuration attributes associated with the pallet category, wherein when a match cannot be identified, a pallet category defined for pallets that cannot be matched is assigned to the pallet; and for each pallet assigned to the pallet category defined for pallets that cannot be matched, send a signal to the automated pallet routing system to cause the pallet to be routed a diversion path.

[0100] In some examples, the pallets 402 for which the pallet evaluation metric is assigned are pallets 402 that have been assigned respective pallet categories that are not the pallet category defined for pallets that cannot bematched, and the automated management system 416 is configured to, for each pallet 402 for which the pallet evaluation metric is assigned: (i) select the repair processing path for the pallet when the condition attributes for the pallet indicate a repair is required and the pallet evaluation metric meets a defined threshold; (ii) select the pallet sorting path for the pallet when the condition attributes for the pallet indicate no repairs are required and the pallet evaluation metric meets the defined threshold; and (iii) select a diversion path for the pallet when the pallet evaluation metric falls below the defined threshold.

[0101] In some examples, the automated management system 416 is configured to assign a batch evaluation metric for the batch of pallets based on a sum of the pallet evaluation metrics assigned to the pallets individually in the batch 401 of pallets.

[0102] In some examples, the configuration attributes include a unique treatment facility identifier associated with a treatment code, wherein the current market evaluation metric for at least some of the respective pallet categories is based at least in part with a category specific unique treatment facility identifier associated with the respective pallet category.

[0103] FIG. 6 illustrates an example of a computing system 170 that may be used to implement one or more of the systems and modules described above, including for example automated management system 416. Computing system 170 may be used in a computer device to execute machine executable instructions that implement one or more of the modules or parts of the modules of system 100.Other processing units suitable for implementing embodiments described in the present disclosure may be used, which may include components different from those discussed below. Although Figure 13 shows a single instance of eachcomponent, there may be multiple instances of each component in the computing system 170.

[0104] The computing system 170 may include one or more processing devices 172, such as a processor, a microprocessor, a general processor unit (GPU), a hardware accelerator, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a dedicated logic circuitry, or combinations thereof. The computing system 170 may also include one or more input / output (I / O) interfaces 174, which may enable interfacing with one or more appropriate input devices 184 and / or output devices 186. The computing system 170 may include one or more network interfaces 176 for wired or wireless communication with a network (e.g with networks 118 or 132).

[0105] The computing system 170 may also include one or more storage units 178, which may include a mass storage unit such as a solid state drive, a hard disk drive, a magnetic disk drive and / or an optical disk drive. The computing system 170 may include one or more memories 180, which may include a volatile or non-volatile memory (e.g., a flash memory, a random access memory (RAM), and / or a read-only memory (ROM)). The memory(ies) 180 may store instructions for execution by the processing device(s) 172, such as to carry out examples described in the present disclosure. The memory(ies) 180 may include other software instructions, such as for implementing an operating system and other applications / functions. There may be a bus 182 providing communication among components of the computing system 170, including the processing device(s) 172, I / O interface(s) 174, network interface(s) 176, storage unit(s) 178 and / or memory(ies) 180. The bus 182 may be any suitable bus architecture including, for example, a memory bus, a peripheral bus or a video bus.

[0106] Although the present disclosure describes methods and processes with steps in a certain order, one or more steps of the methods and processes may be omitted or altered as appropriate. One or more steps may take place in an order other than that in which they are described, as appropriate.

[0107] The features and aspects presented in this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. The described example embodiments are to be considered in all respects as being only illustrative and not restrictive. Selected features from one or more of the above-described embodiments may be combined to create alternative embodiments not explicitly described, features suitable for such combinations being understood within the scope of this disclosure. Where possible, any terms expressed in the singular form herein are meant to also include the plural form and vice versa, unless explicitly stated otherwise. In the present disclosure, use of the term "a," "an", or "the" is intended to include the plural forms as well, unless the context clearly indicates otherwise. Also, the term "includes," "including," "comprises," "comprising," "have," or "having" when used in this disclosure specifies the presence of the stated elements, but do not preclude the presence or addition of other elements.

[0108] All values and sub-ranges within disclosed ranges are also disclosed. Also, although the systems, devices and processes disclosed and shown herein may comprise a specific number of elements / components, the systems, devices and assemblies could be modified to include additional or fewer of such elements / components. For example, although any of the elements / components disclosed may be referenced as being singular, the embodiments disclosed herein could be modified to include a plurality of such elements / components. The subject matter described herein intends to cover and embrace all suitable changes in technology.

[0109] The contents of all published documents identified in this disclosure are incorporated herein by reference.

Claims

Claims:

1. A method for processing pallets, comprising: obtaining, at an automated system, inspection data for each pallet in a batch of pallets based on an inspection of each pallet performed by an automated pallet inspection machine; assigning, using the automated system, a pallet evaluation metric for each pallet based on the inspection data obtained for the pallet; and assigning, using the automated system, a batch evaluation metric for the batch of pallets based on the pallet evaluation metrics assigned to each pallet in the batch of pallets.

2. The method of claim 1 comprising: determining, using the automated system and based on the batch evaluation metric, a supplier evaluation metric for a supplier of the batch of pallets; and storing the supplier evaluation metric in association with a batch supplier identifier for the supplier in a historic supplier evaluation metric database that comprises records of supplier evaluation metrics determined in respect of multiple different suppliers.

3. The method of claim 1 or 2 comprising, using the automated system and based on the batch evaluation metric, automatically determining a compensation amount for electronic transfer for the supplier.

4. The method of claim 2 or 3 comprising:obtaining, at the automated system, batch data for a potential batch of pallets, the batch data indicating: (i) a batch supplier identifier that identifies a supplier of the potential batch of pallets; (ii) an estimated quantity of pallets included in the potential batch of pallets; and (iii) a geographic location of the potential batch of pallets; determining, using the automated system and based on the batch supplier identifier, if the historic supplier evaluation metric database includes a supplier evaluation metric associated with the supplier of the potential batch of pallets and if so, retrieving the supplier evaluation metric associated with the supplier of the potential batch of pallets; assigning, using the automated system, a potential batch evaluation metric for the potential batch of pallets based on: (i) the retrieved supplier evaluation metric; (ii) the estimated quantity of pallets; and (iii) the geographic location of the potential batch of pallets; and performing, using the automated system and based on the assigned potential batch evaluation metric, an action in respect of the potential batch of pallets.

5. The method of claim 4 wherein the action comprises: when the assigned potential batch evaluation metric is determined to exceed a threshold, one or more of: automatically causing an electronic notification to be generated for the supplier of the potential batch of pallets indicating acceptance of the potential batch of pallets;automatically causing an electronic notification to be generated for the supplier of the potential batch of pallets indicating a potential compensation based on the assigned potential batch evaluation metric; and automatically issuing a dispatch notice, including a unique batch identifier, for a vehicle to travel to the geographic location of the potential batch of pallets for pickup thereof.

6. The method of claim 4 or 5 wherein the action comprises: when the assigned potential batch evaluation metric is determined to not meet an evaluation metric threshold, one or more of: automatically causing an electronic notification to be generated for the supplier of the potential batch of pallets indicating rejection of the potential batch of pallets; and automatically causing an electronic notification to be generated for the supplier of the potential batch of pallets indicating a charge for picking up the potential batch of pallets.

7. The method of any one of claims 1 to 6 wherein the inspection data for each pallet comprises parameters indicating of one or more of the following: pallet configuration attributes, including one or more indicators of: a pallet type indicating if the pallet is a stringer pallet or a block pallet; a length of the pallet; a width of the pallet; a height of the pallet; a number of top deck boards; a number of bottom deck boards; spacing between top and bottom deck boards; an identity marking identifying an entity as associated with the pallet; andpallet condition attributes, including one or more indicators of: twisted block; missing block; cracked block; waning block; broken deck board; missing deck board; cracked deck board; waning deck board; missing or covered labelling; discolored wood; waning block; foreign substance on deck boards; and protruding nail; and assigning the pallet evaluation metric for each pallet comprises: assigning the pallet to a pallet category based on the pallet configuration attributes indicated for the pallet in the inspection data; assigning an initial pallet evaluation to the pallet based on the assigned pallet category; mapping the pallet condition attributes indicated for the pallet in the inspection data to repair operations required to fix the pallet condition attributes; adjusting the initial pallet evaluation based on the required repair operations; and determining the pallet evaluation metric based on the adjusted initial pallet evaluation.

8. The method of claim 7 wherein the inspection data for each pallet includes one or more images of the pallet indicating locations of any regions that correspond to one or more of the pallet condition parameters.

9. The method of any one of claims 1 to 8 comprising:determining, using the automated system, a processing plan for each pallet based on one or both of the inspection data or pallet evaluation metric of the pallet, the processing plan specifying one of scrap, repair or no-work required processing; and sending, using the automated system, the processing plan to a controller of an automated pallet routing and repair system for implementation.

10. The method of any one of claims 1 to 9 comprising: obtaining, at the automated system, pallet evaluation metric data representing current pallet evaluation metrics in one or more geographic regions, wherein assigning the pallet evaluation metric for each pallet is further based on the pallet evaluation metric data.

11. The method of any one of claims 1 to 10 wherein the assigned pallet evaluation metric is represented as a monetary evaluation metric.

12. The method of claim 1 comprising: determining, using the automated system, a routing option within a pallet processing facility for each of the pallets in the pallet batch based at least in part on the inspection data for each pallet, wherein the routing options can include options that will divert the pallet from re-entry into a pallet ecosystem; maintaining, using the automated system, historic data that includes pallet configuration attributes as identified in the respective inspection data obtained for the pallets of multiple historic pallet batches, well as a routing data indicating therespective routing options determined for the pallets of multiple historic pallet batches; mining, using the automated system, the historic data to identify groups of pallets that have respective routing data indicating that the pallets were diverted from re-entry into the pallet ecosystem; detecting, using the automated system, any identified groups of pallets that meet a defined pallet number threshold; and generating, using the automated system, an electronic notification indicating any detected identified groups, wherein the electronic notification triggers an analysis as to whether the detected identified groups can be re-introduced into the pallet ecosystem.

13. A pallet processing automated management system comprising: one or more processors; electronic storage storing instructions that, when executed by the one or more processors, cause the automated management system to implement the automated system and perform the method of any one of claims 1 to 12.

14. An automated pallet processing facility, comprising: an incoming pallet handling system for receiving an incoming batch of pallets;an automated pallet inspection machine coupled to the pallet handling system to receive the pallets, the automated pallet inspection machine being configured to generate digital inspection data for the pallets based on an automated visual inspection of the pallets, the digital inspection data for each pallet including (i) configuration attributes for the pallet indicating at least a length and width of the pallet and (ii) one or more condition attributes for the pallet that indicate any defects detected according to a predefined list of possible defects; an automated pallet routing system configured to receive the pallets from the automated pallet inspection machine and selectively route the pallets to one of multiple possible downstream processing paths; and an automated management system coupled to communicate with the automated pallet inspection machine and receive the digital inspection data for the pallets, the automated management system being configured to: assign a respective pallet category from a set of predefined pallet categories to each pallet, based on the configuration attributes for the pallet; for at least some of the pallets: assign a pallet evaluation metric to each pallet based on: (i) a current market evaluation metric for the respective pallet category assigned to the pallet; and (ii) a current market evaluation metric for any repairs required to correct any defects indicated in the condition attributes for the pallet;select, from the multiple possible downstream processing paths, a downstream processing path for each pallet based on the pallet evaluation metric assigned to the patent; and for each pallet, send a signal to the automated pallet routing system to cause the pallet to be routed to the downstream processing path selected for the pallet.

15. The automated pallet processing facility of claim 14 wherein the automated management system is configured to periodically automatically update the current market evaluation metric for each of the pallet categories based on a tracked database of selling values for a preceding duration for pallets belonging to each of the pallet categories.

16. The automated pallet processing facility of claim 14 or 15 wherein: the multiple possible downstream processing paths consist of: (i) a repair processing path; (ii) a pallet sorting path for pallets that are to be to be shipped as usable pallets; and (iii) one or more diversions path that divert the pallet from the repair processing path and the pallet sorting path, the predefined pallet categories each have an associated set of specified configuration attributes, and the automated management system is configured to: assign the respective pallet category to each pallet based on identifying a match between the configuration attributes of the pallet and the set of specified configuration attributes associated with the pallet category,wherein when a match cannot be identified, a pallet category defined for pallets that cannot be matched is assigned to the pallet; and for each pallet assigned to the pallet category defined for pallets that cannot be matched, send a signal to the automated pallet routing system to cause the pallet to be routed to the one of the one or more diversion paths.

17. The automated pallet processing facility of claim 16 wherein: the least some of the pallets for which the pallet evaluation metric is assigned are pallets that have been assigned respective pallet categories that are not the pallet category defined for pallets that cannot be matched, and the automated management system is configured to, for each pallet for which the pallet evaluation metric is assigned:(i) select the repair processing path for the pallet when the condition attributes for the pallet indicate a repair is required and the pallet evaluation metric meets a defined threshold;(ii) select the pallet sorting path for the pallet when the condition attributes for the pallet indicate no repairs are required and the pallet evaluation metric meets the defined threshold; and(iii) select one of the one or more diversion paths for the pallet when the pallet evaluation metric falls below the defined threshold.

18. The automated pallet processing facility of any one claims 14 to 17 wherein the automated management system is configured to assign a batch evaluation metric for the batch of pallets based on a sum of the pallet evaluation metrics assigned to the pallets individually in the batch of pallets.

19. The automated pallet processing facility of any one of claims 14 to 18 wherein the configuration attributes include a unique treatment facility identifier associated with a treatment code, wherein the current market evaluation metric for at least some of the respective pallet categories is based at least in part with a category specific unique treatment facility identifier associated with the respective pallet category.

20. An automated pallet deposit and compensation system comprising: an automated pallet inspection machine for generating inspection data for respective pallets; an automated incoming pallet handling system configured to receive an incoming batch of pallets and automatically feed the incoming pallets to the automated pallet inspection machine; an automated system configured for (i) obtaining the inspection data from the automated pallet inspection machine for each pallet in the batch of pallets from the automated pallet inspection machine, (ii) assigning a pallet evaluation metric for each pallet based on the inspection data obtained for the pallet, (iii) assigning a batch evaluation metric for the batch of pallets based on the pallet evaluation metrics assigned to each pallet in the batch of pallets, and (iv) determining a compensation amount based on the batch evaluation metric and causing the compensation amount to be credited to a supplier of the batch of pallets.

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