What is Palletization?

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An astonishing 2 billion pallets circulate in the U.S. alone, supporting a logistics industry valued at more than $2 trillion. So having a good palletization process is a must. 

Palletized shipments reduce handling costs by up to 50% and are the backbone of inventory management for nearly 90% of supply chains. 

But what exactly does the palletization process entail?

What Should You Know About Palletization?

Palletization is a carefully planned process that can make or break efficiency in logistics. However, there are some terms about palletization that you might need to learn about. Here are a few foundational concepts you need to know when looking into applying a good palletization process:

  • Ti Hi: “Ti Hi” stands for “Tie and High”. This refers to the number of boxes or items on each layer (tie) and the number of layers (high) on the pallet. For example, a lower Ti Hi may be preferred for heavier items to maintain balance, while a higher Ti Hi works well for lighter, compact products.

  • Deck Boards: Deck boards are the horizontal slats on the top and bottom of the pallet that support the load and provide structural stability. The spacing and thickness of deck boards are important, as they impact the weight a pallet can hold and how well it withstands movement without bending. Pallets with tightly spaced deck boards are better for smaller items that need more surface support.

  • Interlocking Pallet Pattern: This stacking technique alternates the boxes’ orientation on each layer to “lock” them into place. Unlike simple column stacking, interlocking patterns add an extra layer of stability, making them ideal for products that may shift in transit. Interlocking is especially helpful for taller loads, as it helps prevent tipping or sliding, offering a more secure stack.

  • Pallet Deflection: Deflection refers to the bending or warping that occurs when a pallet is under a heavy load. Minimizing deflection is important to prevent damage to goods and ensure that pallets can be safely stacked. Pallet deflection is affected by factors such as deck board thickness, the type of material used (e.g., wood vs. plastic), and even the Ti Hi configuration. Monitoring and minimizing deflection helps protect both products and warehouse staff from accidents.

  • Skids: Often confused with pallets, skids are a simpler platform with only a single deck and no bottom deck boards. They’re generally used for static storage rather than movement because they lack the stability needed for forklift handling. However, skids can be ideal for certain static applications and for products that don’t require frequent relocation, as they tend to be lighter and less costly than standard pallets.

Why is Palletization Important in Logistics?

Palletization has a big role in logistics, and it is especially known for these advantages:

Improved Product Handling

With goods stacked on pallets, forklifts, and pallet jacks can easily transport them. This reduces the physical strain on workers and minimizes the time needed to move goods from one place to another.

Enhanced Stability and Protection

When goods are securely arranged on pallets, they are less likely to shift or fall, reducing damage during transport. Tools like plastic film, strapping, and corner protectors further reinforce stability, ensuring products stay in place.

Efficient Inventory Management

Palletization allows for faster and more organized storage, making it easier for inventory management systems to track and manage product location and quantities within a warehouse. This leads to smoother operations and fewer errors in inventory control.

Increased Efficiency in Transportation

Palletized goods are easier to load and unload, enabling quicker turnover in transit. This reduces labor costs and increases overall efficiency in the supply chain.

Adaptability for Different Products

Palletization is adaptable to different product types by selecting suitable materials and stacking configurations, ranging from large, heavy items to perishable products that need particular handling and stacking conditions.

Pallet Stacking Configurations

The way goods are stacked on pallets significantly impacts their stability and the efficiency of space use. 

Below are some common pallet stacking configurations:

  1. Column Stacking: Items are stacked in a straight column. While it maximizes stability, this method is often best suited for uniform products with a flat base, such as boxes of non-perishable items.
  2. Brick Stacking: Similar to building a brick wall, this method involves stacking items in a staggered pattern to enhance stability. Brick stacking provides greater unit load stability, making it ideal for products that need added security during movement.
  3. Interlocking Pattern: By alternating the orientation of each layer, interlocking stacking further increases the stability of the load. It’s particularly useful when handling irregularly shaped products.
  4. Rotating Footprint Stacking: This method rotates each layer to create a more stable, self-locking stack. Although less common, rotating footprint stacking is effective for items with shifting weights or unique shapes.

Pallet Types and Sizes

Since it directly impacts handling, stability, and cost-effectiveness, selecting the right pallet type and size is needed. 

The primary pallet types used in logistics are listed below:

  1. Wood Pallets: These are the most common, typically measuring 48 x 40 inches (GMA standard), and offer high durability and versatility. Wood pallets are ideal for general-purpose use but may require treatment to prevent pest infestations.
  2. Plastic Pallets: Lightweight, durable, and resistant to chemicals and moisture, plastic pallets are ideal for industries with strict hygiene standards, such as pharmaceuticals and food. They have a high capacity-to-weight ratio, making them an efficient choice.
  3. Metal Pallets: Metal pallets are ideal for heavy or high-value loads that require extra security. They’re often used in industries like automotive or aerospace.
  4. Cardboard Pallets: These lightweight, disposable pallets are ideal for one-way shipments or products with specific weight requirements, especially for items sensitive to contamination from other materials.
  5. Solid Deck Pallets: Unlike traditional slatted pallets, solid deck pallets provide a continuous surface, reducing the risk of smaller items falling through gaps. They’re useful for handling products that require a steady surface.

4 Palletizing Methods

Choosing the right palletizing method can influence the efficiency, safety, and cost-effectiveness of warehouse operations. Here are the primary methods:

1. Manual Palletizing

Involves workers stacking goods on pallets by hand. While flexible and suitable for smaller operations, it can lead to worker injuries and inefficiencies in high-volume settings.

2. Semi-Automated Palletizing

Semi-automated palletizing uses machines to assist workers, reducing labor while allowing flexibility. This method can significantly improve throughput rates compared to manual processes.

3. Fully Automated Palletizing

This method uses advanced machinery or robotic palletizers. This way it eliminates the need for human labor in stacking, therefore providing speed, consistency, and higher throughput. While it requires a larger investment, it’s ideal for large operations that handle high volumes of goods.

4. Hybrid Robotic Palletizers

These machines combine robotic arms and automated palletizing, providing flexibility in handling a variety of product shapes and sizes. Re-programming capabilities make hybrid systems adaptable to changing product lines.

Palletizing Safety Tips

Safety is a massive concern in palletization to prevent accidents and ensure secure handling:

  1. Use Banding and Strapping: Straps and bands keep loads secure during movement. This is especially important for stacked products that may shift in transit.
  2. Shrink Wrap and Plastic Film: Wrapping stacked goods with shrink wrap or plastic film adds a layer of stability, preventing products from moving or tipping over.
  3. Avoid Overhang: Products should not extend beyond the edge of the pallet, as overhangs can reduce stability and increase the risk of damage.
  4. Use Corner Protectors and Cardboard Sheets: These add stability and prevent product damage by providing extra support on pallet edges.
  5. Ensure Proper Load Distribution: Always aim for an even distribution of weight across the pallet to reduce the risk of tipping.

Enhance Palletization with Good Warehouse Management

Optimizing palletization is inextricably linked to effective warehouse management. The entire palletization process can be streamlined by putting in place a strong warehouse management system (WMS), which will help you track Ti Hi configurations, monitor pallet deflection, and choose the appropriate pallet types and stacking configurations.

In addition to increasing inventory visibility, a WMS helps staff members stack items correctly, which lowers errors and increases load stability.

Having good automation and data insights set in place can significantly improve palletization efficiency. Pallet conditions can be monitored to ensure safe handling, workflows can be adjusted to avoid bottlenecks, and product weights and dimensions can be analyzed to determine the best stacking patterns.

After all, a well-run warehouse not only facilitates palletization but also increases output, lowers expenses, and helps satisfy the demands of contemporary, quick-paced supply chains.

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