Pallets are the backbone of any warehouse. When you organise your products strategically on each pallet, you’re shielding your stock, safeguarding your team and slashing shipping costs. From there, placing the pallets on top of one another can unlock even more space-saving and cost-cutting benefits. But only if you know how to stack pallets in a warehouse effectively.
This key process isn’t as straightforward as it might appear. And when approached incorrectly, you run the risk of accidents like toppling stacks and falling boxes, as well as inflated freight expenses that can impact profitability.
To help you get it right, we’ve pulled together pro tips and techniques, the most sturdy patterns, and the many perks of doing it properly. Read on to master the craft of safe and efficient pallet stacking.
What is pallet stacking?
Pallet stacking is the process of arranging boxes on a pallet, as well as positioning pallets on top of each other, to ensure secure and efficient storage or shipping.
Proper pallet stacking is a must for any warehouse operation. It can safeguard your reputation, maximise profitability, and most importantly, protect your workers from the dangers of toppling inventory. Get it right, and your goods stay intact during transit, and, even more crucially, your warehouse workers stay safe from the risks that come with unstable stacks.
That’s why your team must understand how to stack pallets in a warehouse properly.
How to stack pallets in a warehouse safely
Mastering pallet stacking is all about balance and precision. The key to safe stacking with forklifts lies in evenly distributing the weight, which not only keeps your stacks stable but also optimises space, letting you get the most out of every square metre.
Always begin with the largest, heaviest pallet on the bottom. It’s also best to stack pallets of the same size and shape to minimise the likelihood of any slipping or tipping.
Double-stacking? Make sure the pallets align in width for extra stability. The more varied your stack, the greater the risk of an accident.
These are just the fundamentals. Keep reading for more pro tips on how to stack pallets in a warehouse.
Check pallets for damage
Before using pallets, it’s crucial to ensure they are in good condition and free from damage. Look for visible signs of wear and remove any damaged pallets from circulation immediately.
This is crucial, as compromised pallets are neither stable nor durable. Protruding nails and splinters not only pose a safety risk to workers but can also tear through the plastic wrap securing the load, leading to shifts and instability. Meanwhile, cracked or broken deck boards can further contribute to an unsteady stack.
Don’t risk it. If a stack collapses, it could result in worker injuries, inventory damage, and significant financial setbacks.
Respect height and weight limits
When stacking pallets, you must stick to height and weight limits to keep both your workers and products safe.
Always check height restrictions before deciding how tall to stack your pallets. Overstacking can be incredibly dangerous, with limits depending on the type of goods and their storage conditions.
Weight limits are equally important. The type and condition of the pallet play a big role in how much weight it can safely handle. For instance, wooden pallets can often support more than 2,200 kg, but that capacity may decrease as the pallet wears out over time. Plastic pallets, on the other hand, usually offer higher weight capacities.
It’s also essential to know the load limits of your pallet jack or forklift. Overloading a forklift can cause it to tip over, posing serious risks to the operator and anyone nearby. Always follow manufacturer guidelines to ensure a safe and efficient warehouse.
Start with the heaviest items
When it comes to how to stack pallets in a warehouse, weight is a core consideration. Always place the heaviest product(s) on the bottom of the pallet, and the heaviest pallet on the bottom of the stack.
Positioning heavier items near the ground supports a lower centre of gravity, boosting stability for your entire stack. Plus, it ensures bulkier items won’t crush or damage the more fragile goods resting on top.
Stack pallets evenly
It’s vital to keep pallets evenly stacked with all products securely within the edges of the pallet. Uneven stacks are a recipe for disaster—whether it’s pallets toppling off forklifts or collapsing mid-transport.
If products stick out, the risk of the entire stack tipping increases dramatically. So keep everything neatly aligned for a safe and stable load.
Strap and wrap
Once your boxes are neatly arranged on the pallet, it’s time to lock them down with strapping bands. This final step is key to keeping your load securely anchored, reducing the risk of items sliding or falling off during transit.
Use two durable straps on each side to secure the load both vertically and horizontally, and don’t forget edge protectors to prevent the straps from damaging the boxes. Make sure there’s a maximum 7.5cm gap between the boxes and the pallet—any more, and the bottom layer might slip around during transport.
After strapping, it’s time for the final layer of defence: shrink wrap. Wrapping the entire pallet gives it extra stability, and you can either do it by hand or with a shrink-wrap machine, depending on how often you need to wrap. To reduce strain when wrapping manually, elevate the load and angle the pallet slightly.
Start at the base, wrapping firmly and overlapping each layer as you go. Don’t be stingy—secure wrapping is key. When you reach the top, give the pallet a stability check. If it still feels shaky, add more wrap until you’re confident everything will stay in place.
Take advantage of lifting equipment
Why rely on brute strength when you can leverage the power of lifting equipment?
Take the strain out of your operations and let machinery handle the heavy lifting for a faster, safer, and smarter warehouse.
Forklifts are central to any warehouse operation, elevating how you manage heavy loads. With their forked platforms designed to lift pallets with ease, they’re a must-have for improving productivity and ensuring smooth operations.
Pallet jacks are also essential. Often called pallet trucks, these versatile tools simplify load movement. With wheeled trolleys and easy-to-use handles or levers, they’re designed for efficiency. And if you want to up your game, electric pallet jacks provide a quicker, effortless option for getting the job done.
Common pallet stacking patterns
The best way to place inventory on a pallet comes down to what you’re stacking.
Generally, however, the key decision is whether to go for column stacking or interlock stacking. These two approaches differ in how boxes are layered, each creating unique patterns that influence the strength and stability of the stack.
To make the right choice, check out the benefits and drawbacks of both pallet stacking methods below:
Interlock stacking
Interlock stacking involves alternating the placement of boxes so each box rests on more than one below, creating a crisscross pattern that enhances support. This method shines when dealing with heavier or high-density loads like canned goods.
Pros
- Delivers unmatched stability
- Handles mixed box shapes and weights with ease
Cons
- Might limit how many boxes you can fit on a pallet
- Uneven weight distribution can put extra pressure on certain boxes, increasing the risk of damage
Column stacking
Column stacking is a straightforward approach where each box is neatly aligned directly on top of the one beneath it, creating a tidy, edge-to-edge pattern. This method is particularly suited for lighter loads or fragile items, keeping them safe and secure.
Pros
- Boosts box stability and strength by 30-50%
- Holds up well against compression from shrink-wrap
Cons
- Taller stacks are more prone to tipping over, especially with lighter materials
How many pallets can you safely stack?
Stacking your pallets too high can lead to dangerous tipping or collapse, so it’s important to know the limits. The height you can safely reach depends on factors like whether the pallets are loaded or empty, the method of stacking, and even the type of materials you’re dealing with.
While there aren’t strict rules for how high you can stack, let your ceiling be the guide. Ensure there’s plenty of room overhead so your stacks stay sturdy and secure, reducing any chance of an accidental toppling.
How to identify poorly stacked pallets
A range of issues can make pallet stacking unsafe. These include racking that isn’t vertically aligned, damaged braces, missing or broken floor fixings, misplaced or faulty splices, and impaired uprights.
Additionally, loose anchor bolts, missing beam connectors or safety clips, overloaded beams, and damaged beams or welds all pose safety risks.
It’s important to regularly inspect your pallet racking to ensure these problems are addressed and prevent potential accidents.
Benefits of correct pallet stacking
From enhanced efficiency to superior safety, knowing how to stack pallets in a warehouse properly can bring invaluable benefits.
Maximise space
Efficient stacking isn’t just about safety—it’s about getting the most out of your space.
By using the right techniques, you can optimise storage in both your warehouse and delivery vehicles. Clever options, like roll cradles, even nest together to save precious floor space for other activities.
Intact inventory
A well-stacked pallet means fewer damaged goods. By building stable stacks, you create a strong foundation that helps prevent products from shifting or falling during storage or transit.
The result? Pristine products reach your customers, boosting their satisfaction and your reputation. Not to mention, less inventory waste and replacement costs.
A safer workplace
Safety thrives when pallets are properly stacked.
Firstly, secure stacks reduce the risk of accidents, helping to protect workers from falling items. Moreover, removing damaged pallets prevents injury from splinters or structural failure.
Last but not least, an organised stacking system helps workers complete tasks with fewer hazards in the way.
Get the right pallet racking for your operations
Understanding how to stack pallet racking in a warehouse is key to supporting worker safety, boosting productivity and protecting inventory.
One final tip?
Don’t overlook the importance of a strong, stable and durable pallet racking system.
While stacking pallets properly is crucial, sturdy and well-maintained racking is just as vital. Even perfectly stacked pallets can become a hazard if the racking itself isn’t up to the task.
At Pallet Racking Sydney, our pallet racking systems are built from the highest quality materials and installed with precision for peak performance. We also offer customised racking solutions tailored to meet the unique needs of your facility.
