In the fast-paced world of logistics, efficiency and safety are equally important. And one, often overlooked, but crucial aspect of warehouse and supply chain management that can truly make or break your operations is correct pallet stacking.
Think about it. Poorly stacked pallets can lead to a domino effect of issues: damaged goods, workplace injuries, and costly delays that impact your bottom line. But by implementing best practices in pallet stacking, you can ensure smooth operations, protect your valuable inventory, and enhance workplace safety.
Why Proper Pallet Stacking Matters
- Prevents Product Damage
Incorrect stacking can lead to products shifting, falling, or being crushed. This results in financial loss and disruptions to the supply chain. Proper stacking helps keep products in good condition all the way from the warehouse to the customer. - Improves Workplace Safety
Pallets that collapse are very dangerous, and can injure workers and damage equipment. Following proper stacking guidelines lowers the risk of accidents and creates a safer workplace. - Reduces Employee Injuries
Loading and unloading pallets that are stacked too high is risky for employees. Handling items above shoulder height raises the chance of injuries, especially to shoulders, arms, neck, and back. Proper stacking and storage helps lower these risks. - Maximizes Storage
Efficient pallet stacking makes the best use of warehouse space, leading to better organization and faster access to inventory. This improves productivity and makes logistics smoother. - Improves Transportation Stability
Securely stacked pallets keep goods stable during transport, which means they’re less likely to shift and cause damage or become dangerous to unload.
Loaded Pallet Stacking and Storage
- FIFO (First In, First Out) Storage System: Pallets must be stored so that the oldest products are picked first, rather than buried under stock that has arrived later. This is ideal for the storage of perishable goods and other products with a limited shelf life, negating the need for manual product rotation within the racking system.
- LIFO (Last In, First Out) System: The opposite approach, where pallets are stacked up and the item on top is picked first. This system is often used when stock rotation is less critical.
Best Practices for Proper Pallet Stacking
- Use High-Quality Pallets
Make sure all pallets are in good condition and free from cracks, splinters, or weak boards that could affect their stability. - Follow Weight Distribution Guidelines
Heavier items should always be placed at the bottom, with lighter, more fragile items on top to maintain balance and prevent crushing. - Stack Evenly and Securely
Align boxes properly without overhanging edges, as misaligned stacks can tip over. Keep loads stable and balanced. - Use Wrapping and Strapping
Secure loads with stretch wrap, shrink wrap, or straps to prevent movement during handling and transportation. - Observe Height and Weight Limits
Don’t stack pallets too high to avoid instability. Always follow warehouse or transport weight limits. - Train Staff on Safe Handling
Regular training helps employees understand proper stacking techniques and safety procedures.
How Not to Stack Pallets
According to SafeWork NSW in their article Pallet Racking Fact Sheet, here are key stacking mistakes to avoid:
❌ Exceed Load Limits
- Do not overload beams or bays as exceeding limits can lead to collapses.
- Avoid using pallets that are too large or too small for the designated racking space.
❌ Alter Racking Without Approval
- Never modify uprights, beams, or braces without manufacturer or engineer approval.
- Do not weld, drill, or attach additional components to the racking structure.
❌ Ignore Damage or Safety Risks
- Do not ignore missing safety clips, bent beams, or damaged braces; replace them promptly.
- Never continue using a rack that has popped out of its upright support.
- Avoid using floor fixings that are damaged or missing; ensure proper anchoring.
❌ Neglect Warehouse Safety
- Do not allow unauthorized personnel to make changes to racking or handling procedures.
- Avoid using incompatible pallets that may slip through or overhang dangerously.
- Never skip routine inspections and ensure compliance with AS 4084 Steel Storage Racking Standards.
How Sipena Logistics Labour Hire Can Help
Ensuring proper pallet stacking requires skilled and trained personnel who understand the importance of safety and efficiency. At Sipena Logistics, we provide experienced warehouse and logistics staff who are well-versed in best practices for pallet stacking, inventory handling, and overall warehouse operations.
Our workforce solutions ensure that your logistics operations run smoothly with minimal disruptions. Whether there is a need for temporary staff for peak periods or permanent skilled workers, our team is ready to support business needs.
We help streamline logistics processes with trained professionals who prioritize workplace safety and productivity.
Contact Us Today
Ensure your warehouse operates at peak efficiency with the right team in place. Contact Sipena Logistics for Container Crew and General Labour Hire today to learn more about how our staffing solutions can enhance your operations.