Pallet Optimization Explained: Packaging, Tips and Benefits
Pallet optimization is the process of maximizing your pallets efficiency in space utilization and handling, while minimizing freight costs. This requires the best use of surface space and stacking height of each pallet when organizing packages onto the pallet. Additionally, all pallet needs should be addressed such as the required safety and security measures of preventing the pallet from shifting in place, this may require the usage of corner boards, stretch films and straps.
Pallet optimization is important because it helps free up limited spaces such as warehouses, stores, distribution centers and in shipment. As a result, many companies can actually save a lot of money on costs as their logistics will run more efficiently.
Pallet optimization may be a requirement depending on where you’re shipping the pallet to. For example, retailers have a specific standard that all pallets need to meet consistently, this helps improve their operations, safely and efficiently store the pallets.
How To Optimize Your Pallets
If you are interested in optimizing your pallet loads, then follow these 9 pallet optimization tips:
Optimize Your Packaging Design Structure
The structural design of your packaging that lays on the pallet matters. Packages that are irregular in shape tend to be difficult to stack and might lead to shifting of products if stacked. In addition, if your packaging is designed to be unnecessarily big, then you are limiting the amount of space you can be using.
Ideally, packages should be uniform on the edges or not have a bulgy or sharp edges/corners, as it can limit the amount of space and stack-ability. Only use the recommended amount of thickness and size for your package, as empty spaces in a package can cause products to be damaged within.
Consider The Best Packaging Material For Pallet Utilization
The packaging material you select will have a direct impact on your pallet optimization, as pallets will be stacked on top of each other while undergoing supply chain conditions. Therefore, it is important for you to pick material that can withstand damage, as damaged packages can create uneven and irregular pallet loads, potentially causing it to shift or fall.
Consider Your Pallet’s Supply Chain Environment Conditions
Environmental conditions such as heat, cold, rain/moisture, shock, pressure, vibration and others all exist in a supply chain environment. Therefore, you should consider preparing your packaging and pallet to withstand potential damages.
Packages will need required protection such as foam, bubble rolls, and other cushioning products. Pallets may need straps, corner boards and stretch film. Your product/pallet and environmental conditions, may warrant you to invest in specialized packaging material. For example, packaging that contains anti-static additives.
Place Heavier Objects At Bottom Of The Pallet
It is important to create a stable base at the bottom of the pallet by placing the heaviest objects at the bottom. This will avoid lighter and fragile goods from being damaged, as well prevent heavier objects from falling.
Stack Up To The Edge And Not Over
Merchandise that is hanging over the edge on the pallet comprises its overall stability. In addition, you may be charged an additional fee or rebilled due to a longer width or length of the pallet. Stack your packages up to or at the edge of the pallet and not over to avoid any issues.
Use Pallet Optimization Software
There are plenty of resources available online to help you optimize your pallets. For example, there are multiple software programs out there such as CAPE, Stack Builder and Best Pallet. Pallet optimization software will show you how to layout your packages on the pallet, while maximizing the safety and space utilization.
Ensure All Edges Are Straight And Uniform
Ideally you will want your pallet to take the shape of a square, so it is easily stackable and weight is equally distributed throughout the pallet. However, one common mistake is stacking your packages into a pyramid, which will distort the balance of weight on the pallet and cause objects to shift.
Use Required Stretch Film
Select the right stretch film depending on your pallet’s size, shape, weight and needs, as stretch can vary from strength and properties. The strength of your stretch film should be able to support and stabilize your pallet throughout the supply chain. Stretch film properties can be altered with additives if special requirements are required.
If Needed Strap Down Your Pallet
For extra security and safety, we recommend you strap down your pallet. Be sure to use the best straps depending on the application. Here is a list of the different types of straps available: polypropylene, steel, polyester, cord and more. It is a good practice to strap down your pallet with two straps in addition to corner boards and slip sheets.
Pallet Optimization Benefits
Pallet optimization can provide your business with many benefits such as:
Improve Safety
Many injuries occur due to unsafe handling of pallet loads. The more uncoordinated a pallet load is set up, the more unstable it will be. Unstable pallet loads are prone to shift, causing packages or the pallet to tumble and fall. Optimized pallets are stable and limit the amount of shifting amongst objects due to a more coordinated layout and load.
Pallets can become more safe with the necessary strapping and stretch wrap. It is important to consider the pallet’s weight, shape and size when selecting protective safety measures for your pallet.
Reduce Shipping Costs
Shipping can get quite expensive when you consider the labor, fuel, handling and other costs associated with it. Therefore, it is important for you to maximize the amount of packages you can ship per pallet, while trying to reduce the amount of pallets and space you use. Overtime, this can greatly reduce your costs if you manage to reduce the amount of trucks (and other forms of transportation) and workers it takes to address your shipping needs.
Faster Loading And Unloading
Loading and unloading of pallets can be greatly improved if all packages are all uniform in size, in addition to having a designated setup on how to lay and stack packages onto a pallet. By keeping your pallet setup optimized and consistent you can improve your operations.
Prevent Product Loss
When pallets or packages fall due to a poor setup can result in inventory loss. Avoid unnecessary costs by minimizing the potential risks.
Improve Space Utilization
Pallet optimization will help you free up space in your warehouse and on your freight. Your customers and business partner will thank you by being efficient on how you ship your products.
Need Assistance With Your Pallet Optimization And Packaging?
If you are interested in packaging and having it optimized ready to ship to you or your customers, then contact Brown Packaging today to get started.
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