What is palletizing? Types, products, and process (End-to-end guide)

Whether you’ve spent years in logistics or are just getting started, one thing’s clear: palletizing is just one piece of the supply chain puzzle — but it plays a crucial role in getting goods out the door fast and without any unpleasant surprises at their destination.

That’s why, in this article, we’ll walk you through the step-by-step process of palletizing, explore the different types of palletizing solutions, and help you choose the right one for your business.

So, what exactly is palletizing?

Palletizing is the process of stacking goods onto a pallet to keep them stable, secure, and space-efficient. Whether it’s moving boxes of chocolate or crates of pharmaceutical products, palletizing helps goods travel safely through the supply chain.

While palletizing started out as a labor-intensive, manual task, it has come a long way. With the rise of automation, more businesses are switching to robotic or cobot palletizers to meet growing demand without putting extra pressure on their workforce.

How palletizing works, step by step

Palletization typically begins with choosing the right pallet—one that can handle the weight and dimensions of your load. Next, items are arranged in a way that balances weight and maximizes the space on the pallet. Once stacked, the load is secured using straps or wrap to prevent shifting during transit. The ultimate goal of a palletizer is to keep everything steady and compact on a pallet.

1. Pallet selection

Selecting a pallet that’s solid enough for your products heavily depends on the industry you’re in. Are you in the food or pharmaceutical industry? Then plastic pallets are the way to go — known for their durability, resistance to moisture, and cost-effectiveness.

Wooden pallets are another great option. They’re affordable, strong, and the most common choice across many industries.

Metal pallets, while less common and more expensive upfront, are ideal for very heavy or high-temperature loads, like in the automotive or chemical industries.

2. Arranging the goods and distributing weight

Arranging products properly across a pallet is absolutely critical to ensure they arrive safely at their destination. Typically, heavier products are placed first at the bottom, with lighter ones stacked on top.

With a Smart Palletizer, you can control the stacking patterns based on your products, lift heavy weights (up to 30 kg), and ensure each pallet is stacked perfectly — every single time.

3. Securing the load

After the goods are properly stacked onto a pallet, they need to be tightly secured with straps, shrink wrap, or stretch film to ensure they stay firmly in place during transport.

4. Labeling and documenting pallets

The final step in palletizing is labeling the pallets with their contents, weight, destination, and any special handling instructions. Good labeling makes sure everything gets handled the right way, speeds up customs clearance, and helps you track goods more easily across the logistics chain.

The different types of palletizing solutions

There’s no one-size-fits-all approach when it comes to palletizing. Your choice depends on your product range, volume, and available space.

Manual palletizing

Manual palletizing is still common in smaller operations. It’s hands-on and doesn’t require much setup, but over time it can take a toll on your team and leave room for inconsistency in your operations, especially with growing labor shortages.

Robotic palletizing

Robotic industrial palletizers are built for speed and are ideal for mixed case palletizing.

They’re a strong fit for high-throughput lines where every second counts. However, since they’re fixed in place and require safety fencing, they’re often less flexible than…

Cobot palletizing

Cobot palletizers, like our very own Smart Palletizer, bring the best of both worlds. Designed to work alongside people, they’re compact, easy to install, and ideal for handling a wide range of box types for a single-SKU pallet. Whether you’re dealing with open crates or sealed boxes, a cobot palletizer can adapt quickly to boost your end-of-line process.

What kinds of products can you palletize?

With the right setup, almost anything. Boxes, crates, open or closed, light or heavy — a wide variety of products can be palletized with ease. Our Smart Palletizer, for example, is equipped with a unique fork gripper that easily lifts even open boxes. It’s a practical solution trusted by companies in food, pharma, bakery, and more.

Palletizing in action: stacking chocolate at Heinerle-Berggold

Heinerle-Berggold, a German chocolate maker, swapped manual labor for a Smart Palletizer to keep up with production and reduce strain on their team. Installation was quick, and the results were immediate: the palletizer now covers three shifts of manual palletizing. Today, their employees work more comfortably, while the cobot handles the heavy lifting.

Choosing the best palletizing solution for your needs

When selecting a palletizing solution, it’s important to evaluate your specific needs. Product type, volume, available space, and budget all play a role. If your operation handles high volumes and requires flexibility, a cobot palletizer can offer quick setup, easy adaptation, and an ROI in less than a year.