While much of our work takes place after the pallet is assembled we still take a pretty close look at pick and build processes. In this way we can often make small tweaks or recommendations that can have far larger consequences for both product damage and pallet optimisation.
The initial footprint of the pallet contents is as good a place to start as any. Here, it depends on the type of goods being packed. Even uniform pallets should be checked for gaps, and new patterns experimented with. Column patterns are suited to like products such as cartons or uniform box shapes. Other times a Tetris approach for items in bags or diverse loads will fill in space and effectively cut down on pallets needed.
Then there is the way boxes are combined on the pallet. Intuitively ‘brick stacking’ box arrangements seems to make sense. It’s what our parents taught us when we were playing with toy blocks as children. It appears to create a far stronger ‘whole’ from the individual parts. And it looks good when done right.