Pallets
Manual Palletization

Manual Palletization

Manual palletization gives you full control over which items go on each pallet, which pallet type to use, and how items are arranged. Use this when you need to build specific pallets for particular orders, customers, or destinations.

Opening the Palletize Panel

There are two ways to open the Palletize Panel:

  1. Right-click one or more items in the Items Panel → select "Palletize" from the context menu
  2. Select items in the Items Panel, then click the "Palletize" button in the panel header

The Palletize Panel opens as a full-width modal with settings on the left and a 3D preview on the right.

Panel Layout

Left Side — Settings

  • Pallet Name — editable text field. Defaults to "Pallet #N". Change it to something meaningful (e.g., "Customer A — Fragile", "Order #4821 Layer 1").
  • Pallet Type — dropdown showing your active pallet types. Select the physical pallet you will use.
  • Items List — checkboxes for each item. Check items to include them on this pallet, uncheck to exclude. Use All / None toggle for quick selection.
  • Add Items (+) — opens an inline picker to add items from your item library with search.
  • Pallet Limits — displays the selected pallet's max height, max payload, and overhang allowance for reference.
  • Packing Pattern — dropdown to choose the item arrangement strategy: Best Fit, Column, Interlock, or Pinwheel.
  • Layer Rotation — dropdown to rotate every Nth layer 90 degrees: Off, Every 2 layers, Every 3 layers.

Right Side — 3D Preview

A live 3D viewport showing the pallet with items arranged by the solver. Camera presets (3D, Top, Front, Side) let you inspect the arrangement from any angle. Click individual items in the preview to see their name and weight in a tooltip.

Building a Pallet

Follow these steps to build a loaded pallet:

1. Select Items

Check the items you want on this pallet. The panel shows each item's name, dimensions, weight, and quantity. If an item has quantity greater than 1, all units are included.

2. Choose Pallet Type

Select the pallet type from the dropdown. The Pallet Limits section updates to show the selected type's capacity. Make sure your items will fit within the height and weight limits.

3. Choose Packing Pattern

Select a packing pattern: Best Fit (default), Column, Interlock, or Pinwheel. The pattern controls how items are arranged on the pallet surface.

4. Choose Layer Rotation (Optional)

If you want alternating layer orientations for better stability, select layer rotation: every 2 or every 3 layers.

5. Auto-Pack

Click Auto-Pack to run the pallet solver. The 3D preview updates to show the packed arrangement. Statistics appear below the preview:

  • Fill % — how much of the pallet's available volume is used
  • Weight — total weight of items on the pallet
  • Height — stack height from the pallet surface
  • Items Placed — number of items successfully placed (vs. total)
  • Time — solver execution time

6. Review and Adjust

Inspect the 3D preview. If items were left unplaced, consider changing the packing pattern, removing large items, or switching to a larger pallet type. You can re-run Auto-Pack as many times as needed.

7. Create Pallet

Click Create Pallet to save the pallet to your plan. The pallet appears in the Items Panel as a group with an amber header showing the pallet name, type badge, item count, weight, and fill percentage.

After creating a pallet, run the container solver (Quick Plan, Smart Plan, or Max Fill) to place the pallet inside the container. The solver treats the loaded pallet as a single composite item.

AI Analysis (Optional)

After Auto-Pack completes, an AI Analysis button appears. Click it to get a Claude-powered explanation of the packing arrangement, suggestions for improvement, and risk assessment. See AI Analysis for details.

Next Steps

Pallet LibraryPalletize All