Abstract: A manual-operated cigarette material pallet-loading system was improved to solve the problems, such as low efficiency, operation site disorder, and potential safety risks arisen from mixed man and forklift operation. The improved system was mainly composed of a pallet separator, conveyors, a turntable, an elevator, shuttle vehicles, two-layer steel platform, etc. The operators at 5 stations successively put cigarette material on the pallets, the loaded pallets were conveyed to the input end of stackers by conveyors, cigarette material was transferred to storage positions by stackers, then the online material pallet-dispensing and stocking were completed. The results of application showed that after improvement, the efficiency of cigarette material pallet-dispensing and stocking increased from 35 to 46 pallet/hour, the working time of forklift decreased from 6 to 0.5 hours/day, the function of online manual pallet-dispensing was realized, the simultaneous operation of operators and forklift was avoided and the safety of pallet-dispensing site was improved, while maintenance work was reduced.