Pallet Loading Overview

Palletization is the process of grouping cargo items onto standard pallets before loading them into a container or truck. Instead of placing individual boxes directly on the container floor, you stack them onto pallets first — then load the pallets as units. This is the standard workflow in warehousing and freight logistics worldwide.

LOP supports a complete two-stage loading workflow: first pack items onto pallets, then load pallets into containers.

Why Palletize?

Palletizing your cargo before container loading offers several practical advantages:

• Faster loading and unloading — forklifts move entire pallets in seconds, versus handling individual items one by one
• Better stability — items grouped on a pallet and secured with stretch wrap move as a single rigid unit
• Standard dimensions — pallets have known footprints (e.g., 1200 x 800 mm EUR), making container space planning predictable
• Less handling damage — items stay in their packed arrangement from warehouse to destination
• Easier inventory tracking — each pallet is one unit in your shipping manifest

The Two-Stage Workflow

LOP's pallet system works in two stages:

Stage 1 — Pack Items onto Pallets

Select which items go on each pallet, choose a pallet type and packing pattern, and run the pallet optimizer. LOP arranges items on the pallet surface respecting height limits, weight capacity, and stacking rules. You can do this one pallet at a time (manual palletization) or let LOP assign all items to pallets automatically (Palletize All).

Stage 2 — Load Pallets into the Container

Once your items are palletized, run the container solver as usual. LOP treats each loaded pallet as a single composite item — with the combined height, weight, and footprint of the pallet plus its cargo — and places it in the container alongside any remaining floor items.

Quick Start

The fastest way to get started with pallets:

1. Add items to your plan as usual (manually, from the library, or via import)
2. Select a pallet type — go to the Containers page, switch to the Pallets tab, and check the pallet types you want to use
3. Palletize — either right-click items and choose "Palletize" for manual control, or click "Palletize All" in the Items Panel header for automatic assignment
4. Choose a pattern — select Column, Interlock, Pinwheel, or Best Fit depending on your cargo
5. Auto-Pack — click Auto-Pack to run the pallet solver and see the 3D preview
6. Create the pallet — save it to your plan
7. Solve — run the container solver to place pallets in the container

What LOP Handles Automatically

When you palletize items, LOP automatically:

• Respects the pallet's maximum stack height and payload capacity
• Honors item fragility (fragile items placed on top)
• Enforces orientation locks (this-side-up items stay upright)
• Calculates combined weight and dimensions for the container solver
• Renders realistic 3D pallet geometry with wooden boards, stringers, and fork entry gaps
• Displays STEP/CAD items as actual 3D models on the pallet surface

Next Steps

• Pallet Library — standard pallet types and how to select them
• Manual Palletization — build pallets one at a time with full control
• Palletize All — automatic bulk assignment of all items to pallets
• Packing Patterns — Column, Interlock, Pinwheel, and Best Fit explained
• Managing Pallets — edit, lock, reorder, duplicate, and delete pallets