Investigation of Pallet Stacking Pattern on Unit Load Bridging

Abstract

Considering the effect of packages during pallet design will reduce costs and improve the sustainability of the supply chain. Currently, many mechanical interactions between the pallet and the package product are not being considered during the pallet design process. This study investigates the effect of the magnitude and type of interlocking between layers of packaged products. The bending of the pallet supporting a unit load of corrugated boxes was measured under four common support conditions, warehouse rack storage spanning the pallet width and length, fork tine support across the pallet width, and floor stacking. Five different pallet stacking patterns were analyzed from column stacking to fully interlocked stacking. It was determined that interlocking packages reduces pallet deflection up to 53%. This is more significant for lower stiffness pallets and when the payload carried by the pallet is greater than the rated load capacity of the pallet. Increasing the magnitude of the interlocking reduces the deflection of the pallet by 11.6%. These results provide a guideline on improving pallet design and help further the understanding of the interaction between pallets and the orientation of packaged products placed on the pallet.