the ultimate guide on how to load pallets faster

Carriers and other operators in logistics have a demanding schedule and must load trailers quickly to keep things running smoothly and punctually. Unfortunately, the task presents them with a range of challenges:

Manual Handling Bottlenecks

Manual handling bottlenecks are extremely frustrating. Loading pallets manually ties up several employees at once and can feel as if the team isn’t progressing through its workload. Even small delays can ripple throughout the process and hurt output.

Warehouse Congestion

Warehouse congestion creates safety hazards, confuses workers, stops or slows down the flow of inventory and prevents orders reaching customers on time. Lack of storage space, a poorly designed layout and inefficient technology and systems all create congestion in the warehouse. This increases labour costs and overheads, hurting the business’s bottom line.

Double-stacked, unevenly loaded pallets can become unstable and damage products. If they’re not secured properly, they become unsafe, so comply with weight restrictions and industry regulations.

Before double stacking pallets, always check the pallets are designed for double stacking. Check they have the necessary structural integrity and load bearing capacity. Employ proper loading techniques, such as even weight distribution, and use appropriate bracing.

What is the maximum stacking height?

When deciding a safe height to stack pallets, consider the pallet payload’s support characteristics, information from the manufacturer, local conditions and the stacking pattern.

Generally, the Health and Safety Executive (HSE) recommends pallet loads are no higher than the longest base dimension of the pallet. The HSE also recommends the absolute maximum height, if stacking empty pallets, is no more than six times the narrowest dimension of the bottom pallet after consulting the manufacturer, assessing the stacking pattern and compression characteristics of the payload and confirming the pallet design meets the stacking height required.

Forklifts can damage products and trailers. Not aligning the forklift’s prongs with the goods correctly can drive the forks directly into the product or cause loads to fall if the load is off centre, damaged or loose, the forks are bent or there’s no load backrest.

When entering the trailer, forklifts can cause damage if they don’t load correctly. They can cause the trailer to upend, trigger lateral instability, cause the landing gear to collapse or inflict load bed damage.

When loading pallets, distribute the weight evenly and place bulky items or heavy ones on the lowest layer for a lower centre of gravity. This enhances overall stability. The bottom layer should be strong and level enough to support the pallet(s) on top of it.

Vertical stacking is the most straightforward loading pattern for pallets, but it requires more securing so the pallets don’t shift during transit. Interlocking patterns provide stability because they lend excellent resistance to side-to-side movement; however, this style of arrangement reduces the strength of pallets and should be avoided.

Secure loads with straps of wrap for transit

Before loading a pallet onto the vehicle, you must secure it to form a single unit. Do this with shrink wrapping, banding or strapping. Make sure the load can’t slide on the pallet. If it does, the restraint system for the pallet and the ones around it could fail. Stretch wrap is one of the best methods because it clings tightly to items and can support more weight.

When carrying pallets on vehicles that have van bodies, secure the load with lashings if there are gaps between the pallet and the headboard, between the pallets and the vehicle sides or gaps between the pallets. If you can’t use lashings, use packaging material or dunnage to stop the pallets moving.

If you’re looking for a Skate and Track Loading System for your business, download a copy of our free Skate and Track Systems brochure. 

From benefits to best practice, discover how to lighten the load with our Skate and Track System brochure today!

If you’re looking for the right block pallet loading solution for your truck/trailer, download a copy of our free Modular Rollerbed System: Block Pallets leaflet. 

From benefits to best practice, discover how to lighten the load with one of our Modular Rollerbed System: Block Pallets today!

If you’re looking for a Modular Rollerbed: Powered Cargo Roller for your business, download a copy of our free Modular Rollerbed: Powered Cargo Roller brochure. 

From benefits to best practice, discover how to lighten the load with our Modular Rollerbed: Powered Cargo Roller brochure today!

Our cost effective systems boost your logistics and allow you to achieve a return on investment (ROI) within 18 to 24 months.

That’s because due to greater efficiency the systems lend your logistics, this leads to lower operational costs. Fewer personnel become necessary to conduct loading and unloading, freeing staff up for other tasks and lowering your labour costs.

Reduce product damage & accidents

Using one of our loading systems improves the safety of your loading process, ensuring no accidents for your employees or damage to products you are handling. This ensures no order delays, ruined reputation, or fines/claims for injuries.

Around the world, we’re known as the number one; the global leader in loading and unloading solutions. This is not only because we are the largest but also the first too; we've been pioneering loading solutions since 1962.

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