Palletising

Palletising is the process of organizing goods on a pallet to form a unit load for handling, storage, and transport. It can be performed manually or with automated equipment, and is used to improve efficiency in warehouses, distribution centers, manufacturing plants, and retail logistics.

Pallets form the foundation of palletised loads. They are usually made of timber, but plastic and metal pallets are common where higher hygiene, moisture resistance, or durability is required. Common sizes include EUR/EPAL 800x1200 mm and North American 48x40 inches (1219x1016 mm). The choice depends on load weight, handling equipment, environmental conditions, and product stability.

Palletising patterns vary to achieve stability and efficient use of space. Block stacking (solid columns), interlocking brick patterns, and layer-by-layer approaches are common. The aim is even weight distribution, a stable center of gravity, and safe handling. Goods are often secured with stretch film, strapping, or shrink wrap; slip sheets may be used to reduce pallet usage in some setups.

Standards and best practices guide palletised loads. International and regional bodies define pallet dimensions, quality, and load stability requirements; examples include EUR/EPAL pallets in Europe and GMA pallets in North America, along with ISO guidelines for unit loads.

Automation and planning increasingly influence palletising. Manual methods coexist with robotic palletisers, conveyors, and software that optimize stacking patterns, wrapping, and layer sequencing to maximize space and minimize damage. Training and safety protocols address handling equipment, weight limits, and stacking heights.

Applications span manufacturing supply chains, wholesale and retail distribution, food and beverage, and e-commerce fulfilment, where efficient palletising contributes to throughput, inventory control, and damage reduction.