Pallet Optimization / Pallet Configuration

Pallet optimization is the process of figuring out exactly how products should be arranged on a pallet to maximize the number of cases or units while staying within weight limits and handling constraints. It's the foundation of accurate load building: if your pallet counts are wrong, everything downstream – freight class, weight, carrier pricing, trailer utilization – is wrong too.

A proper pallet configuration accounts for case dimensions (length, width, height), cases per layer, layers per pallet, total pallet weight, and whether the product can bear additional weight on top. For mixed-SKU pallets, the calculation becomes more complex – different case sizes, different weight distributions, and different stackability rules all interact. Temperature-controlled products often have additional constraints, such as requiring airflow space between layers or prohibiting contact with non-refrigerated goods.

When pallet configuration is done manually – often by a warehouse team member referencing a printed spec sheet or estimating from experience – errors are common. Overstating pallet counts means the carrier shows up to a heavier-than-expected load. Understating them means wasted trailer space. Incorrect freight class declarations on LTL shipments lead to re-class fees that can double the cost of the shipment. These aren't edge cases; they're everyday occurrences for shippers without product-level data in their planning systems.

Automating pallet optimization requires a maintained item master with accurate dimensions, weights, and stackability flags for every SKU. When this data feeds directly into the load building process, pallet counts and weights are calculated precisely – eliminating guesswork and the costly errors that come with it.