Robotic palletizer stacking cartons on a pallet
Solutions Industries Pallet building
Packing, loading, and stowage

Intelligent pallet building for stable and efficient loading units

Software-assisted load-carrier building for homogeneous, layer-based, and mixed pallets under a wide range of real operational constraints.

The challenge is not only to place as many items as possible on a pallet. Loading units must remain stable in transport, practical in picking, aligned with unloading logic, and compatible with product-specific rules.

What needs to be co-optimized today

Stability, load distribution, and product protection instead of pure surface utilization

Sequencing, unloading logic, and store processes directly inside pallet building

Clean handoff into loading, transport, and operational system landscapes

What pallet building needs to deliver today

Pallet building is much more than a stacking problem

Geometric constraints, height limits, and overhangs must be respected reliably

Weight, center of gravity, and load-bearing capacity determine transport stability

Mixing rules, product protection, and stacking logic must not slow operations down

Unloading sequence, shelf logic, and store processes already matter during pallet building

Labeling, scanability, and warehouse handling affect practical usability

Pallet building needs to stay connected to loading, tour logic, and downstream transport

Three example pallets with boxed and bottled goods
Supported pallet types

From homogeneous to sequenced

Homogeneous pallets

Layer-based pallets

Heterogeneous pallets

Sequenced store pallets

Display and promotion pallets

Optimization logic

What our software optimizes in pallet building

We combine rule-based optimization with experience from 3D packing, transport planning, and store replenishment to generate pallet recommendations that are mathematically sound and operationally robust.

Geometry and space usage

Dimensions, pallet types, maximum height, overhangs, and allowed orientations are considered so floor space and height are used well without violating constraints.

Weight and load distribution

The software optimizes weight distribution and center of gravity so pallets are not only dense, but also well-balanced and transport-safe.

Stability and stackability

Support areas, layer formation, bearing limits, and stable patterns are treated as first-class planning rules.

Sequence and process logic

Optimization can be aligned with unloading sequence, picking logic, route order, or store structures whenever process suitability matters more than pure density.

Your benefits

More stable loading units, better processes, less manual planning

Benefit 1

Higher utilization of pallet space and loading height

Benefit 2

More stable loading units

Benefit 3

Less product damage

Benefit 4

Faster warehouse and shipping processes

Benefit 5

Better store- and customer-ready pallets

Benefit 6

More transparency and standardization in planning

Rules and restrictions

What can be modeled directly

Different pallet types and load carriers
Maximum height, weight, and floor load
Allowed item orientations
Overhangs and free spaces
Load-bearing limits and stacking bans
Fragile or pressure-sensitive items
Sequence requirements for tour, unloading, or shelf placement
Mixing bans for certain product groups
Different load carriers arranged on a studio floor