Palettenstapelung

Palettenstapelung refers to the arrangement and stacking of pallets in warehouses and distribution centers. It is a fundamental process for the efficient storage and retrieval of goods and is often governed by safety regulations and industry best practices.

The concept originated in the early 20th century with the rise of industrial manufacturing and logistics. Initially, pallets were stacked randomly, but as inventory systems evolved, standardized methods such as the Single Side Stacking (SSS), Multiple Side Stacking (MSS) and Compartment Stacking were developed to improve stability and access.

Modern pallet stacking relies on automated storage and retrieval systems (AS/RS) as well as manual stacking guided by weight limits and load distribution calculations. Regulatory bodies such as OSHA in the United States and the European Union’s safety directives provide guidelines that require safe stacking heights, proper load cushioning, and fire safety measures.

Key factors in effective pallet stacking include the pallet type—wood, plastic, or stackable—, the product type, and the handling equipment used. High shafts and slotting create opportunities for taller stacks but also increase the risk of overloading or shifting. Many companies use pallet integrity inspections, load-testing, and the "stackable pallet number" to ensure consistent load tension.

Despite its routine nature, pallet stacking can be a major source of workplace accidents if guidelines are ignored. Implementing training programs, standard operating procedures, and regular audits reduces incidents. Continual assessment of pallet placement by using software analytics can further optimize space utilization, resulting in cost savings and improved supply chain resilience.