Palletizing

Palletizing is the process of arranging goods on a pallet to form a unit load for handling, storage, and transport. The objective is to create a stable, optimally shaped load that can be moved by forklifts, pallet jacks, or automated equipment and protected during movement. Palletized loads simplify storage, improve space utilization, and support automation in warehouses, distribution centers, and manufacturing facilities.

Pallets serve as the base platforms for unit loads. They are made in several materials, with wood being the most common due to cost and availability; plastic pallets are reusable and moisture-resistant; and metal pallets are used for heavy, high-value, or rigid loads. Pallets are standardized in size across regions: in North America the typical pallet is 40 by 48 inches (1016 by 1219 mm); in Europe the common size is 800 by 1200 mm. Regional sizes vary, and some industries use nonstandard pallets. Wooden pallets intended for international shipping are often heat-treated or fumigated to meet ISPM 15 pest-control requirements.

Unitized loads are created manually or with automated palletizing systems. Manual palletizing is common for irregular items or low volumes, while robotic palletizers and layer-forming equipment handle high-volume operations. Load patterns include column stacking for compactness and interlocking (brick) patterns for stability. Securing methods such as stretch wrap, banding, and corner boards help prevent shifting during transit. Slip sheets can be used as alternatives to full pallets in some cases.

Key considerations include weight distribution, load height, pallet condition, and compatibility with handling equipment. Regular inspection, safe lifting procedures, and adherence to relevant standards support safe, efficient palletizing and transport.