Pallets – the cornerstone of efficient warehouse automation

From origins to the present – why pallets matter in warehouse logistics

Pallets serve as essential platforms for storing, handling and transporting products.

The history of pallet manufacturing dates back to the late 19th century when simple wooden structures began their evolution into today’s effective tools for managing large volumes of goods.

Currently, over 5 billion pallets are produced annually worldwide. Europe, in particular, has seen significant growth in europallets production. In 2022, EPAL achieved a record-breaking output of 109.05 million europallets.

Key advantages of using pallets:

• transport efficiency – pallets simplify handling with forklifts, stackers and conveyor systems;
• storage optimization by stacking on several levels;
• minimizing the risk of damage to goods during storage and transit.

Pallet sizes: Why europallets are a universal solution

Pallet dimensions play a critical role in choosing the best option for storing and transporting specific goods.

The most common pallet types by size include:

• europallet (1200×800 mm): the most widely used standard that complies with EPAL requirements. Versatile and suitable for a broad range of goods;
• US standard pallet (1200×1200 mm): frequently used in e-commerce, retail and distribution sectors;
• FIN or Finnish pallet (1200×1000 mm): common in Europe for transporting goods with special safety requirements.

Europallets stand out as a universal solution for efficient storage and transportation of products regardless of the scope of activity and business size. These durable pallets are designed to handle intensive use and are subjected to phytosanitary treatment to ensure safety in industries with strict hygiene requirements. Compliance with EPAL (European Pallet Association) standards guarantees their quality and durability. Their standard dimensions make them compatiable with both loading equipment (trolleys, forklifts, stackers) and automated storage systems (pallet racks, sorting lines). Additionally, their size ensures efficient space utilization in trucks, containers and narrow warehouse aisles. For instance, a 90 cubic-meter eurotruck with a minimum body width of 2.45 m can accommodate up to 33 europallets.

Wood, plastic or metal: choosing the right pallets for your warehouse

Pallets come in various materials, each suited to specific needs:

• wooden pallets – affordable, reusable and recyclable; damaged pallet boards can be reprocessed for extended use;
• plastic pallets – lightweight, resistant to moisture and chemicals;
• metal pallets – known for their exceptional load capacity and durability;
• paper pallets – made of biodegradable corrugated cardboard. Lightweight, eco-friendly, designed for single-use applications.

The optimal choice of pallets for your warehouse depends on operational requirements, the type of goods, and the storage and transportation conditions. Here’s how different industries can benefit from specific pallet types:

Retail and distribution: wooden or plastic pallets with standard dimensions, such as europallets, are suitable for automated systems. Their durability supports frequent use and easy transportation in high-turnover requirements.

Food industry: plastic pallets are the preferred choice due to their easy-to-clean surfaces, compliance with hygiene standards, antibacterial properties, and suitability for use in refrigerated trucks.

Pharmaceutical industry: plastic pallets are ideal meeting strict environmental and hygiene standards. Certified pallets with unique markings, labels or ISPM 15 stamps ensure compliance with international standards and safe handling of sensitive products.

DIY sector: wooden pallets are cost-effective and available, making them a practical option. Their recyclability and alignment with sustainable practices make them a popular choice in this sector.

What are smart pallets? Do you need them in your warehouse?

Smart pallets are modernized with advanced tracking systems like RFID, GPS or IoT sensors. These technologies offer significant advantages, including:

• real-time monitoring of goods’ movement and location;
• enhanced inventory management;
• reduced risk of loss.

For companies prioritizing warehouse automation, smart pallets are becoming essential. They integrate seamlessly with WMS systems, boosting efficiency and simplifying cargo handling.

Innovative solutions by KAPELOU: efficient automation of pallet warehouses

Rising warehouse costs and the growth of industry and commerce have driven the need for vertical logistics. Automating the process of handling products on pallets accelerates order picking and supports business scalability.

KAPELOU, a manufacturer of pallet equipment and automated warehouse systems, offers comprehensive solutions for automating pallet warehouses.

Our solutions significantly increase the warehouse productivity, ensuring process continuity and maximizing operational efficiency.

The full range of automation solutions tailored to optimize various areas of pallet warehouses includes:

• driven pallet conveyors: enable safe and efficient transport of goods on pallets;
• vertical conveyors: accelerate the lifting and lowering of pallets between levels in multi-tier warehouses;
• palletizing/depalletizing and packaging solutions: streamline shipping operations and enhance order fulfillment efficiency;
• robotic manipulators: deliver precise and rapid pallet handling while reducing reliance on manual labor.

Tailored solutions for your business needs

KAPELOU’s design team develops unique solutions that align with the specific requirements of your warehouse, industry and operational processes. We take into account all the nuances to deliver maximum efficiency. As a general contractor we take full responsibility for the project’s outcome, ensuring quality and mitigating risks at every stage.

Optimizing warehouse space – make every square meter work for you

With escalating storage costs and limited warehouse space, vertical logistics has become a critical component of modern storage solutions.

There are several types of pallet racking available:

• gravity pallet racking – utilizes gravity for seamless pallet movement;
• frontal racking – provides convenient access to goods stored at multiple levels from the front;
• deep storage racks – ideal for storing large quantities of similar goods, allowing forklifts to maneuver within the racking system;
• cold zone pallet racks – designed to withstand low temperatures and resist corrosion;
• mobile racks – enable pallets to be moved along rails.

Among these, gravity pallet racks stand out for their efficiency in utilizing space and ensuring the fast movement of goods on pallets without additional energy costs. KAPELOU’s modular gravity racks are easily scalable making them an excellent choice for high turnover industries where speed and adaptability are critical.

KAPELOU: Precision in every detail

Successful warehouse automation requires precise equipment and solutions designed to meet your specific operational challenges. Incorrectly chosen configuration can create bottlenecks that disrupt logistics processes. At KAPELOU, we analyse every detail of each project and offer solutions that perfectly align with your goals.

Are you ready to make your warehouse perfect?

Contact KAPELOU and we will implement automated systems to provide stable, rapid and efficient handling of palletized goods. Our solutions optimize every stage of warehouse operations, increasing productivity and reducing costs.

Modern automated systems from KAPELOU allow you to significantly speed up cargo handling, optimize warehouse space utilization and minimize manual labor. When you choose KAPELOU, you gain a partner who will help you create the warehouse of the future – technologically advanced, cost-effective, and dependable.