Palletizing pallet pattern chart illustrated with images

Whether you palletize manually or use an automated system, you want to make sure you’re using the right palletizing pattern that will help you package your products safely and reduce damage and returns. If you’re wondering what a palletizing pattern is, it’s essentially a visual representation of the most optimized arrangement of products on a pallet that maximizes space utilization and ensures stacking stability.

How to calculate how many boxes will fit on a pallet?

To calculate how many boxes can fit on a pallet, consider box size, carton type, and number of boxes in a unit load. The first rule is to place as many cases in layers as possible without protrusions, unless they are generally unavoidable and permitted by the manufacturer’s customer. An interlocking pattern is used between the different pallet layers to maximize stability. However, if the cases are large (stable) and the main constraint is the loading capacity of each case (loads can be higher if pressure is transferred across the edge of the case), the same pallet configuration (column loading pattern) is used. . The number of layers is determined to match the pallet load capacity, maximum unit stack height (racking or ergonomic constraints), or the number of boxes the customer requires per unit load.

Palletizing Pattern Chart

There are several palette patterns to choose from. This section presents seven pallet load configurations that we believe are optimal.

1. Interlocking pattern

One challenge when stacking containers in a vertical arrangement is preserving the load during transport. As a result, many people use an interlocking pattern that “locks” the containers in place by staggering their positions.

This pattern is suitable for products that need to be stacked securely. Often used for heavier loads.

2. Partially linked pattern

In a partially interlocked pattern, the small boxes overlap, but not all of them. It consists of a base layer and an interlocking top layer joined by columns. Compared to fully interlocked structures, this improves the strength of each vertically aligned layer by up to 45%. Partially interlocked patterns are best suited for light loads and products that do not require significant stability.

3. Block or split block pattern

The block pattern represents the pallet pattern of the column arrangement. Each box is stacked on top of the box below it in the same order. This method works for certain items, but lack of interlocking can cause items to fall off. It all depends on what you are palletizing.

A variation of this pattern is a split block that divides the pallet into two sections. The first section is the central column of the box that holds all the containers together. Around this pillar is a second section with boxes stacked on top of each other, similar to a block pattern.

This is useful for products of various sizes as it prevents the product from tipping over.

4. Brick pattern

With a brick pattern, you don’t stack the boxes in the same way as you would with a column arrangement. Rather, they are built one by one, alternating layers, like a brick wall.

One downside to this approach is that the weight is distributed unevenly at the weakest point of each box. This method is not recommended for heavy loads because it puts too much stress on the bottom layer.

5. Row or split row pattern

This is similar to a brick pattern, but each layer is rotated 90 degrees compared to the layer below. It provides additional interlocking for stability, but is not as complex as the pinwheel pattern (see below).

Split Row is a variation of this pattern that provides additional stability. Split rows allow you to have a standard row design, but place one box in each row in a different orientation to hold the rest in place.

This is useful for products of various sizes as it prevents the product from tipping over.

6. Pinwheel pattern

A pinwheel is a pattern that interlocks at regular intervals to form a wheel-shaped box.

You can use this type of pattern if your product tends to shake during transportation. The spacing between boxes allows for some movement, which can be helpful depending on what you are palletizing.

It is also useful for products of different sizes as it prevents the product from tipping over.

7. Column stacking pattern

Column stacking increases box stability by 25-30%. Distribute the weight evenly over the strongest points of each box.

One problem with this approach is that it relies on ties or shrink wrapping for stability. The structure itself does not provide stability. Since all the boxes are directly on top of each other, this is the only way to prevent them from tipping over during transport.

The road to palletizing success is planning. Experiment with different palette layouts and see how they perform. If you have a heavy box, you may want to consider using a pattern that provides additional support, such as an interlocking or pinwheel pattern. The size of the box is also important. When palletizing large boxes, you need a pattern that can accommodate while maintaining stability.

Finally, consider the contents of the box. When palletizing fragile items, it is recommended to minimize movement to avoid damage. For example, a pinwheel pattern may not be the best choice. Don’t think you can simply set up a palletizing operation once and leave it at that. You may need to change your pallet pattern over time to ensure continuous improvement.

How Robots Help Palletize

Robots have long been used in large manufacturing companies for palletizing to optimize shipping processes. These companies benefit from the consistent motion of palletizing robots, saving valuable time per pallet and significantly improving efficiency due to higher delivery volumes.

For smaller companies or those with a wide range of products, robotic palletizing is relatively new. Recently, collaborative robots (cobots) have made the benefits of robotic palletizing accessible to almost everyone.

Cobots improve delivery efficiency by:

• consistency: Cobots perform the same tasks consistently, ensuring boxes are always placed correctly on pallets at a consistent speed.
• accuracy: Cobots position boxes at precise angles to maintain accuracy throughout the process.
• Ease of Programming: Collaborative robots are easy to program, so even people who normally perform palletizing work can program them, allowing them to flexibly respond to product line changes.

Automated palletizing solutions allow you to significantly optimize your palletizing operations and accelerate delivery.