How Warehouse Automation is Shaping Pallet Requirements and the Role of System Pallets

The rapid adoption of warehouse automation systems is revolutionizing logistics and supply chain operations worldwide. The growth of e-commerce, labor shortages, and limited warehouse space have accelerated the need for automation in warehousing and distribution. As Automated Storage and Retrieval Systems (AS/RS) and pallet shuttle systems become more prevalent, pallet selection has become a critical factor in the success of automated warehouse systems, ensuring smooth operations and minimizing disruptions. 

What Are the Key Factors Driving Warehouse Automation? 

Several key factors are driving warehouse automation or smart warehouse integration, including the steady growth of e-commerce, labor shortages, and warehouse space constraints. Let’s explore each factor: 

• E-commerce Growth: The expansion of e-commerce throughout the 2010s, and the surge in 2020, increased the demand for faster and more efficient order fulfillment. Customers now expect quicker shipping times and higher accuracy, putting pressure on warehouses to automate processes. 

• Labor Shortages: Rising labor costs and a shrinking workforce make automation a necessity for keeping operations running efficiently. Automated systems help offset the lack of available workers, reducing dependence on manual labor. 

• Space Constraints: Automation allows for higher-density storage and better utilization of available warehouse space, which is especially important as space becomes more limited and expensive. 

What Are the Different Types of Warehouse Automation Systems? 

Warehouse automation addresses the challenges above, but what are the key systems being implemented? Two of the most popular solutions are AS/RS (Automated Storage and Retrieval Systems) and Pallet Shuttle Systems. 

• AS/RS (Automated Storage and Retrieval Systems): A computer-controlled system that uses cranes to reach products at all heights and depths. This advanced mechanical system is designed to place and retrieve pallets, managing large volumes of inventory while enhancing storage density, speed, and accuracy. 
• Pallet Shuttle Systems: Automated carts that move along racks within storage lanes to retrieve and store pallets. This system is ideal for high-density storage and improves safety by reducing the need for forklifts to enter aisles. Unlike AS/RS, pallet shuttle systems are simpler and focus on increasing storage density rather than fully automating all aspects of the storage and retrieval process.  

The Importance of Pallet Selection in Automated Systems 

With these advanced systems powering smart warehousing, even a small hiccup can cause significant delays. One of the biggest culprits for such disruptions is the quality of the pallets themselves. 

Automated systems thrive on consistency, so feeding the system uniform, high-quality pallets is essential for smooth operations. Newly manufactured pallets are the most ideal option as they are defect-free, ensuring reliability and avoiding system failures. Recycled or remanufactured pallets can also be suitable, but they must be thoroughly inspected before use to ensure they are free of defects that could disrupt operations. 

Common defects to watch for in recycled pallets include: 

• Missing or broken stringers. 

• Broken or missing bottom deck boards. 

• Protruding nails. 

• Incorrect pallet sizes. 

These defects can damage machinery, halt production, or even pose safety risks for workers. 

The Role of System Pallets in Automation and Smart Warehousing 

Now that we understand why automation is growing rapidly in warehousing and distribution, and why consistency in pallet quality is so important, let's discuss system pallets and their role in automation. 

System pallets, also known as helper pallets or pallet retrieval boards, are used internally for automated operations. These pallets have a flush design, eliminating the risks of broken boards or protruding nails that could injure workers or halt production. 

 Stack of UFP Packaging system pallets with hand holes for easy handling

System pallets are the perfect complement to automated systems as they sit smoothly on conveyor belts, supporting the seamless movement of pallets through various processes. They also streamline automation by eliminating the need to transfer goods between inbound and system pallets -- simply place the palletized items directly onto the system pallet for automated handling. 

These pallets are durable and designed for repetitive use in both AS/RS and pallet shuttle systems. 

UFP Packaging Manufactures System Pallets 

With the explosive growth of automated smart warehouses, the transformation in how manufacturers, warehousing, and distribution companies operate is undeniable. Since pallets are a critical part of this transformation, it is essential to choose a provider that delivers consistent quality solutions to ensure smooth integration with automated systems and maximize efficiency. 

UFP Packaging manufactures system pallets with a range of customizable options to enhance your automated processes. Custom features include: 

• Hand holes for easy manual relocation. 

• Barcode notches on the edges for product identification. 

• Eased perimeters at the top and bottom with radius corners for long life and minimized handling damage. 

With more than 80 plants nationwide, we have the capacity to meet needs both small and large. 

Click here to request a quote or schedule a consultation.