Repalletizing

Repalletizing is the process of transferring goods from one pallet to another, typically to consolidate loads, replace damaged pallets, or adapt to different carrier specifications. It is distinct from palletizing, which involves forming unit loads on pallets from individual items.

The typical workflow includes receiving a load, inspecting the existing pallet for damage or contamination, removing items from the original pallet, selecting a suitable replacement pallet, reassembling the load on the new pallet with correct orientation and stability, securing with stretch wrap or bands, labeling, and recording the change for inventory and traceability. Depending on scale, repalletizing may be performed manually, semi-automatically, or on automated lines.

Reasons and benefits include improving compatibility with transportation modes or customers, maintaining load stability, facilitating cross-docking or warehousing throughput, extending pallet life, and supporting pallet pooling or reuse programs. Standards and considerations vary by region; ISPM 15 treatment may be required for wooden pallets used in international shipments, and pallet dimensions and weight limits differ (for example, North American pallets commonly measure 40 by 48 inches, while European pallets are typically around 800 by 1200 mm). Good practice also emphasizes even weight distribution, appropriate stacking height, and proper securing of loads.

Equipment and safety considerations involve using forklifts, pallet jacks, stretch wrap machines, and strapping tools, along with operator training, PPE, and adherence to forklift and manual handling safety protocols to minimize injury and product damage. Applications are common in manufacturing, distribution centers, and third-party logistics, where repalletizing supports efficiency and load integrity.