Palletizing pattern charts explained with pictures

Whether you’re palletizing by hand or using an automated system, you want to make sure you’re using the correct palletizing pattern because it helps you safely package your products, reducing damage and returns. If you’re wondering what a palletizing pattern is, it’s basically a visual representation of the most optimized arrangement of products on a pallet that maximizes space utilization and ensures load stability.

How to calculate how many boxes fit on a pallet?

To calculate how many boxes will fit on a pallet, consider the dimensions of the cardboard, the type of cardboard and the number of boxes in the unit load. The first rule is usually to place as many cases as possible on a layer, without any overlap, unless unavoidable and accepted by the manufacturer’s customer. Interlocking patterns are used between different pallet layers to maximize stability. However, the same pallet configuration (column stacking pattern) is used if the boxes are large (and stable) and if the main limitation is the carrying capacity of each case (the load can be higher if the pressure is transferred to all edges of the boxes). The number of layers is set to match either the load capacity of the pallet, the maximum height of the unit load (rack or ergonomic constraints) or the number of cartons the customer needs per unit load.

Palletizing templates

There are several pallet patterns that you can choose from, in this section we will introduce you to 7 pallet load configurations that we think are optimal.

1. Interlaced pattern

When stacking containers in a vertical arrangement, one of the problems is the preservation of the load during transport. As a result, many people use an interlocking pattern that “locks” the containers in place by changing their positions.

This pattern is ideal for products that you need to stack securely. Often used for heavy loads.

2. Partially interlaced pattern

In a partially connected pattern, the sme boxes overlap, but not all of them. It consists of a base layer and an interconnected upper layer that is connected by columns. Compared to a fully bonded structure, this improves the strength of each vertically aligned layer by up to 45%. Partially woven patterns are best for lighter loads and products that don’t require as much stability.

3. Block or split block pattern

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

A variant of this pattern is the split block, which involves dividing the palette into two parts. The first part is the central column of boxes that hold all the containers together. Around this column is a second section where the boxes are stacked on top of each other, just like a block pattern.

This is useful for products of different sizes as it prevents them from tipping over.

4. Brick pattern

With the Brick Pattern, you don’t stack the cartons the same way you would with a column layout. Rather, you stack them one on top of the other, alternating between layers, like a brick wall.

One disadvantage of this approach is the uneven weight distribution at the weakest point of each carton. We do not recommend using this method for heavy loads as it puts too much stress on the bottom layer.

5. Line or split line pattern

It’s like The Brick Pattern, but we rotate each layer 90 degrees compared to the layer below it. It provides extra blocking for stability, but is not as complex as The Pinwheel Pattern (see below).

The Split Row is a variation of this pattern that provides some extra stability. With a split row, you have a standard row design, but you place one box in each row in a different orientation to lock the rest in place.

This is useful for products of different sizes as it prevents them from tipping over.

6. Pinwheel pattern

A pinwheel is an interlocking pattern with some gaps formed by wheel-shaped boxes.

You can use this type of pattern when the product tends to shift during shipping. The gaps between the boxes allow for some movement, which can be beneficial depending on what you’re palletizing.

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

7. Pattern folded column

Stacking the columns increases the stability of the box by 25-30%. It distributes the weight evenly to the strongest point of each box.

One problem with this approach is that it relies on tie downs or shrink wrap for stability – the structure itself provides no stability. They are the only thing that keeps the boxes from falling apart in transit because all the boxes are right on top of each other.

The way to success with palletizing is to plan. Experiment with different pallet layouts to see how they work. If you have heavy boxes, you’ll want to use a pattern that offers extra support, such as interlocking patterns or pinwheel patterns. The size of the boxes is also important. If you’re palletizing large boxes, you’ll need a pattern that can accommodate them without sacrificing stability.

Finally, consider the contents of the boxes. If you’re palletizing fragile items, you’ll want to minimize movement to prevent damage. Here, for example, a pinwheel pattern might not be the best choice. Don’t believe that you can simply set up your palletizing task once and leave it at that. You may need to change the palette patterns over time, allowing for continuous improvement.

How robots can help with palletizing

Robots have long been used for palletizing in large manufacturing companies to optimize the shipping process. These companies benefit from the consistent movements of the palletizing robots, which save valuable seconds on the pallet, leading to a significant increase in efficiency due to high shipment volumes.

For smaller companies or companies with diverse products, robotic palletization is relatively new. Collaborative robots (cobots) have recently made it possible for almost everyone to benefit from robotic palletizing.

Cobots increase transportation efficiency by:

• Consistency: Cobots perform the same task consistently and ensure that the boxes are always placed correctly on the pallet and at the same speed.
• Accuracy: Cobots place boxes at precise angles, maintaining accuracy throughout the process.
• Ease of programming: Cobots are easy to program, allowing them to be programmed even by those who usually perform palletizing tasks, making them flexible for changes in product lines.

Using automated palletizing solutions can significantly optimize your palletizing tasks and speed up your shipments.