warehouse insider
Vimaan develops AI-powered computer vision solutions that automate warehouse validation, inspection, and inventory workflows. Rather than replacing existing WMS, WCS, or automation systems, Vimaan provides real-time visual intelligence that helps customers verify inventory, shipments, pallet quality, and warehouse operations.
The PalletSCAN product family is designed to automate pallet validation across receiving, storage, production, and shipping workflows using a common software platform and analytics environment.
| Product | Primary Function |
| PalletSCAN 360 | Multi-sided pallet inspection and shipment verification |
| PalletSCAN 3D | Dimensioning, overhang, lean, Ti-Hi counting and SKU validation, and pallet profiling |
| PalletSCAN 100-D | Drive-by pallet face capture, LPN/SKU validation; quality checks |
This application note focuses on pallet profiling using PalletSCAN 3D, which is designed for inline dimensioning, lean detection and load integrity validation on conveyors and with AGVs/AMRs.
Modern warehouses and distribution centers increasingly rely on automated conveyors, automated guided vehicles (AGVs), sorters, and AS/RS systems to achieve high throughput and predictable performance. These systems assume that incoming pallets and parcels meet strict physical requirements, including correct dimensions, stable geometry, proper orientation, and acceptable load condition.
In reality, upstream variability introduces risk. Pallets or parcels may be over-height, skewed, leaning, partially collapsed, or unstable. When these items enter automated material handling systems unchecked, the result is often reduced throughput, unplanned stoppages, jams, or costly manual intervention.
To maintain the operational flow and automation gains, operators need a way to automatically profile items as they move through the facility, without slowing operations.
Pallet (and parcel) profiling goes beyond simple barcode identification. It creates a digital twin of each load while scanning in motion.
This includes:
This information can be evaluated in real time against system limits or stored for audit and analytics.
Material Handling systems are often already in-place. On conveyors, items are already constrained in speed, direction, and spacing; making them ideal candidates for automated inspection. Similarly, AGVs/AMRs make tightly controlled and predictable maneuvers.
Key drivers:
Preventing induction/handling failures (Ensuring loads meet robotic handling tolerances)
Rather than reacting to failures inside automation, conveyor and AGV-based profiling allows operations to shift left and detect problems at entry points.
Key capabilities include:
The system is designed to operate at typical conveyor speeds and spacing, supporting both average and peak throughput conditions.
Operational Outcomes
Customers deploying conveyor-based profiling typically see:
Most importantly, automation behaves as designed because the inputs are controlled.
Production-Tested Accuracies*
| Parameter | Accuracy |
| Depth Accuracy (<=0.5 in) | > 98% |
| Width Accuracy (<=0.5 in) | > 98% |
| Height Accuracy (<=0.5 in) | > 98% |
| Front / Back OverHang Accuracy (<=2.0 in) | > 98% |
| Left OverHang Accuracy (<=2.0 in) | > 98% |
| Right OverHang Accuracy (<=2.0 in) | > 98% |
*Accuracies can depend on speed of travel, shrinkwrap or other protrusions, etc.
All profiling events are automatically stored within ViewDECK, Vimaan’s web-based visualization and analytics platform.
Operators can:
By combining dimensional measurements with synchronized imagery, ViewDECK provides a permanent digital record of each inspected load, simplifying troubleshooting and customer claim resolution.
To see how PalletSCAN 3D can integrate with your conveyor or AGV setup and prevent automation failures at the source, Contact Us.
Q. What is pallet profiling and why does it matter for warehouse automation?
Pallet profiling is the process of capturing true 3D dimensions, geometry, and load condition of a pallet while it moves through a facility. For warehouses using automated conveyors, AS/RS, or AGVs, incoming pallets must meet strict physical requirements. A pallet that is over-height, leaning, or has overhang can cause conveyor jams, sorter misroutes, or AS/RS failures. Profiling at entry points prevents these problems before they propagate downstream.
Q. How does PalletSCAN 3D profile pallets without stopping the line?
PalletSCAN 3D uses computer vision and 3D reconstruction to profile pallets inline as they move at normal conveyor speeds. It does not require the pallet to stop or rotate. The system captures true 3D dimensions, detects lean and skew, identifies overhang, and generates pass/fail signals to the WMS, WCS, or PLC in real time.
Q. What does PalletSCAN 3D actually measure?
It captures length, width, and height with accuracy within 0.5 inches at over 98% reliability. It also measures volume, detects front/back and left/right overhang to within 2 inches, identifies lean and skew relative to gravity and the conveyor centerline, and flags asymmetrical or unstable load builds. Every scan is image-synchronized for traceability.
Q. Where in the workflow should pallet profiling happen?
Pallet profiling should happen at induction points wherever pallets enter an automated system. This includes conveyor induction from receiving docks, AS/RS entry points, and AGV/AMR handoff zones. The goal is to catch non-compliant pallets before they reach automated handling, not after a failure has already occurred.
Q. How are profiling results stored and reviewed?
All profiling events are automatically logged in ViewDECK, Vimaan’s web-based analytics platform. Operators can search historical profiles, review dimension data and images, investigate exceptions, and export records for audits or customer claim resolution. Data is available across facilities for trend analysis.
Q. Does pallet profiling work with AGVs and AMRs, not just conveyors?
Yes. AGVs and AMRs make tightly controlled, predictable movements, which makes them well-suited for automated profiling. PalletSCAN 3D can be configured to profile loads carried by AGVs and AMRs using the same gate-based approach used on conveyors.