Palettization

Palettization, also palletization, is the process of arranging goods on a pallet to create a unit load for handling, storage, and transport. The practice standardizes packaging dimensions and load geometry to enable efficient manual and automated handling, protect contents, and maximize space utilization in warehouses and freight networks.

Pallet types and materials vary. The most common are stringer pallets and block pallets, typically made of wood, plastic, or metal. Common pallet sizes include the EUR-pallet (800 by 1200 mm) in Europe and the 48 by 40 inch pallet in North America, with regional variations such as 600 by 800 mm or 1000 by 1200 mm. Wood pallets may require ISPM15 treatment for international transit. Pallets are designed to bear static and dynamic loads appropriate to the cargo and mode of transport.

Pattern and stability are central concerns. Palettization uses patterns that maximize stability and minimize damage, such as uniform layer placement, interlocking or column-stacking arrangements, and appropriate weight distribution. Goods are secured with stretch wrap, banding, or corner boards, with attention to even load height and avoiding overhang.

Automation and optimization are increasingly common. Palletizing robots and collaborative robots (cobots) perform placement tasks, often guided by software that optimizes load patterns, gravity centers, and space efficiency. Software may also coordinate inventory control, pick allocation, and packaging validation.

Applications span manufacturing, wholesale, distribution, and e-commerce. Benefits include improved handling efficiency, reduced product damage, better workplace safety, and easier inventory management. Standards and best practices continue to evolve with changes in transport regulations and automation technologies.