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Layer Pickers with Top Patented Technology for Load Splitting
Layer pickers are advanced pallet-handling machines engineered to split and transfer layers of products with precision, speed, and safety.
Unlike traditional forklift attachments, which require manual operation and offer limited efficiency, our patented layer pickers are fully independent machines designed to deliver higher automation and performance in demanding warehouse environments. By lifting and separating entire layers, they streamline operations such as re-palletizing, load splitting, and order preparation without exposing operators to unnecessary risks.
At Top Industries Inc., we offer three innovative models of layer pickers, each tailored to different levels of throughput and automation. From flexible solutions suitable for mixed product handling to high-capacity systems capable of managing a large number of layers per hour, our equipment adapts to the unique needs of logistics providers, food & beverage companies, and pharmaceutical manufacturers. The benefits are substantial: improved safety, reduced labor costs, faster workflows, and enhanced product integrity. With more than 36 patented solutions, Top Industries sets the benchmark in load-splitting technology, ensuring businesses achieve maximum efficiency and reliability in every operation.
Layer Picker – Side Press Splitter
Separates layers by gently pressing the load from the sides.
Layer Picker – Falcon Wings Split.
Mobile layer picker and pallet exchanger equipped with extendable blades.
Layer Picker – Pantera
Designed to press each layer from all four sides while integrating a pallet magazine.
Why Our Layer Pickers Are Different from Forklift Layer Picker Attachments
Our machines are a far superior alternative to forklift layer picker attachments, offering much faster and safer operations while ensuring products remain undamaged. They not only divide stacks of goods with precision but also handle pallet exchange efficiently by gently pressing and lifting the load, allowing the pallet underneath to be replaced. Using two side platforms—or four, depending on the model—the system securely lifts the products, transfers them smoothly, and places them onto the new pallet with maximum care. Read the blog article here.
Types of Layer Pickers
At Top Industries Inc., we have developed three advanced models of layer pickers, each engineered to provide superior performance compared to traditional forklift attachments.
Classic Layer Picker Model with Two Side Pressors
The classic version of our layer picker uses two lateral pressors to gently secure and lift product layers. This model is ideal for standard applications where reliability, safety, and simplicity are key. It ensures smooth handling without damaging goods, making it suitable for a wide range of industries.
Classic Layer Picker with Two Side Pressors and Extendable Blades
This enhanced model builds upon the classic version by integrating extendable blades. The blades allow the machine to handle more complex or unstable loads, ensuring greater flexibility when separating products stacked in varying formats. It provides added versatility for warehouses and distribution centers that manage diverse product types.
Automatic Layer Picker System AI-Integrated with Pallet Dispensers
The most advanced option is our automatic layer picker equipped with sensors, cameras, and artificial intelligence. This system recognizes each layer of the load, enabling the operator to select specific layers for separation with unmatched accuracy. Thanks to four-side pressing, the lifting process is secure, reliable, and fully automated. Designed to integrate seamlessly into production lines or operate alongside high-bay warehouses, this model includes pallet dispensers for continuous workflow. It is fully customizable based on automation requirements, making it the ultimate solution for high-throughput operations.
Use Cases of Layer Pickers in Different Industries
Layer pickers are versatile machines that bring significant advantages across multiple industries where safety, efficiency, and product care are essential. In the food and beverage sector, they are widely used to handle bottles, cans, cartons, and other delicate packaging. By ensuring hygienic pallet changes and precise layer separation, they help companies maintain quality standards while keeping operations fast and reliable.
Food & Beverage
In the food and beverage sector, they are widely used to handle bottles, cans, cartons, and other delicate packaging. By ensuring hygienic pallet changes and precise layer separation, they help companies maintain quality standards while keeping operations fast and reliable.
Pharmaceuticals
In the pharmaceutical industry, layer pickers guarantee contamination-free processes when transferring medicines, vials, or medical devices. Their ability to operate without direct manual handling not only protects sensitive products but also ensures compliance with strict regulatory requirements.
Logistics & Distribution
The logistics and distribution sector also benefits from the flexibility of layer pickers. They simplify operations such as re-palletizing mixed loads, preparing orders with different product layers, or replacing damaged pallets—all while reducing downtime and increasing overall throughput.
Manufacturing
In manufacturing environments, layer pickers enhance workflow efficiency by enabling operators to remove or separate specific layers of products without dismantling the entire stack. This makes it easier to perform quality inspections, repackaging, or partial shipments, allowing companies to save both time and labor while maintaining high levels of productivity.
Across all these industries, the common results are faster operations, safer workplaces, and better protection for products.
Finding the right machinery
for you in 3 steps
We have a customer-focused approach that enables us to prioritize their needs with a dedicated offer creation process.
Start NowGet in touch with our experts
STEP 1
Answer the questionnaire
We provide you with a questionnaire asking for details about your operational needs, such as the type of product you handle. This helps us understand how we can assist you.
STEP 2
Our consultants will find the best solution for you
Through the information you provided, our consultants will analyze your information to build a customized offer based on your needs choosing among over 50 different pallet changer models.
STEP 3
Boost your production processes
With our tailored solutions, you can significantly boost your productivity by choosing a system that perfectly aligns with your specific needs and operational goals.
Suitable for every brand,
including yours
Food
3PL
Cosmetics
Beverage
Pet Food
Pharma
Our layer pickers are engineered to adapt seamlessly to the needs of any company, regardless of brand, product type, or packaging format. Designed with flexibility in mind, they ensure smooth load handling across diverse industries such as food & beverage, pharmaceuticals, logistics, and manufacturing. By combining advanced technology with patented safety systems, our machines deliver reliable performance for every business—making them the ideal solution for companies that require efficiency, hygiene, and product protection in every layer separation and pallet exchange.
Why Choose Top Industries Inc.
As the U.S. market leader in pallet-handling technology, Top Industries Inc. brings unmatched expertise to the design and manufacturing of advanced layer pickers. Backed by over 36 patented solutions and decades of innovation through our parent company Toppy, we provide equipment that goes far beyond traditional forklift attachments. Whether you need a versatile semi-automatic model or a fully integrated AI-driven system with pallet dispensers, our layer pickers deliver the highest levels of safety, efficiency, and reliability—helping your business achieve faster operations, reduced costs, and superior product protection.
Leading the USA
in pallet changing solitions
We stand out with our range of over +36 patented pallet changer models, offering tailored solutions to fit various products, workflows, and spaces, making us the leading choice for American companies.
Choose The USA LeaderGet in touch with our experts
+36 PATENTED SOLUTIONS
Layer Picker FAQ – Everything You Need to Know
What is a layer picker and how does it work?
A layer picker is a modern material-handling system designed to lift one or more layers of products from a pallet and transfer them onto another. Instead of moving the entire load, it uses precise gripping mechanisms—such as clamps, side pressors, or blades—to separate and place product layers quickly, safely, and accurately.
Which industries use layer pickers the most?
Layer pickers are especially common in the food retail and distribution sectors, where they can handle up to 98% of product types stored in grocery warehouses. They are also widely adopted in pharmaceuticals, logistics, and manufacturing, particularly in automated environments where mixed-SKU pallet building is required to improve speed and accuracy.
How much productivity improvement do they provide compared to manual handling?
Layer picking systems can improve throughput by up to 400% compared to manual operations—going from about 250 cases per hour with manual labor to more than 1,200 cases per hour with automated systems. This translates into faster turnaround times, reduced labor costs, and significantly higher operational efficiency.
What are the main safety and quality benefits?
By eliminating heavy manual lifting, layer pickers reduce the risk of workplace injuries while ensuring consistent and ergonomic operations. They also protect product integrity—fragile goods such as bottles, cartons, or medical supplies are handled more gently and reliably than with traditional forklift attachments.
Can layer pickers be integrated into automated warehouse systems?
Yes. Modern layer pickers integrate seamlessly with Warehouse Management Systems (WMS) and Warehouse Control Systems (WCS). They can be combined with conveyors, pallet dispensers, and other automation solutions, becoming an essential component of Industry 4.0 smart logistics.
Can layer pickers operate in cold storage or freezer environments?
Absolutely. Many advanced systems are built to operate in extreme temperatures, ranging from −28 °C to +40 °C, making them suitable for refrigerated warehouses, cold-chain logistics, and frozen food handling.