Block stacking pallets is a secure and efficient warehouse storage solution that involves stacking palletized loads (unit loads) of products with the same SKU on top of each other on the warehouse floor, usually in bays that are single-deep or double-deep lanes.

This method is particularly suitable for fast-moving products and materials that can be safely stacked with one SKU, providing a secure and reliable storage solution. The process can require careful planning and regular review of your warehouse layout to prevent honeycombing or dead space in your warehouse.

Benefits of Block Stacking Pallets for Warehouse Solutions

Block stacking pallets offers several benefits, starting with its low cost and remarkable flexibility. It does not necessitate an investment in a pallet racking system. It can be set up wherever suitable warehouse floor space is available, providing the ability to adapt as warehouse storage requirements change. For many operations, it is faster for forklifts to stack and unstack from block storage than navigating selective pallet racking systems to put loads in and out of storage. The efficiency and adaptability of block stacking make it a popular choice in many industries.

However, there are precautionary notes. Block stacking pallets is only viable if loads are stable and safe. Safe stacking techniques are vital to maintaining the integrity and safety of your supply chain. Consider your pallet stacking method and review forklift stacking best practices to make sure you’re stacking heavy pallets safely. 

Other options, such as pallet racking or stacking frames, are better for more unstable loads. Additionally, forklift operators must stack loads squarely. Off-center stacking will compromise the stability of the stack. 

Quality Pallets Matter When Stacking Pallets

1. Pallets need to be strong. When it comes to stacking, pallets must be strong enough to support the weight of all the loads above. This is what pallet designers refer to as static load capacity. For example, if four 2,000-lb loads are vertically stacked, the bottom pallet must have a static load capacity of at least 8,000 lbs. Static load capacity is typically not limited for good condition commonly used pallets, such as 48”×40” GMA style pallets, but check with your pallet supplier to verify.

2. Pallets need all deck boards intact. Pallet quality was cited as a contributing factor in a recent fatality case involving block stacking. If a pallet is missing components, the stability of the block stack can be compromised. For example, a missing bottom outside board will make the stacked loads more tippy. If there are missing center cluster boards, bearing pressures will be more concentrated and more likely to result in the crushing of the load below.

3. Wood shards and exposed fasteners can puncture the product. Punctures can be a problem for loads containing liquids or powdered goods. For instance, if an exposed nail punctures a bottle, it will create a leaker. Leading liquid can quickly degrade the stacking strength of corrugated containers and put your block stack and employees at risk. Likewise, powders or granules leaking from punctured bags can cause loads to gradually tilt.

4. Some loads require purpose-built custom pallets and crates. Some loads are more challenging to stack and require custom features such as cradles, tie-downs, pallet collars, or custom crating. For irregular loads such as motors or lawn tractors that are generally not stackable, custom pallets for stacking will help ensure the necessary load strength and product protection. Loads of inherently unstable items, such as cylindrical items like pipes, are another challenge best met through a design consultation.

The bottom line for block stacking is that it is convenient and safe when done correctly, but never leave it to chance like a game of Jenga. If you’re interested in warehouse management solutions, why not contact the national sales team at PalletOne to discuss what safe stacking could look like for your operation?