Palletize All

Palletize All builds eligible families of matching items in whole layers across your selected pallet types. Standard palletization sizes the pallet count from volume, weight and layer limits; a partial layer goes on a separate pallet.

Palletize All is remainder-aware: for a quantity item whose units are already partly on pallets, only the unpalletized remainder is considered — units on existing pallets are never taken apart or double-counted. Items that are fully palletized are skipped entirely.

How to Use It

1. Open the ⋯ overflow menu in the Items Panel header and select "Palletize All"
2. In the dialog that opens, configure:
   • Pallet types — select which of your active pallet types to use (at least one required)
   • Clear existing pallets first — whether to remove current unlocked pallets before reassigning (locked pallets are always preserved)
   • Container-aware palletization — when sizing pallet columns for your selected containers’ height, LOP compares with the ordinary whole-layer alternative using the number of units Best Fit (Auto) actually packs per layer when that count can be measured. Leave it off for standard whole-layer sizing; both alternatives are compared with container structure enabled, keeping the higher placed cargo volume, then fewer pallets on a volume tie.
   • Solve mode — pallet builds always use Quick Plan in layer mode; this selection does not change the pallet build.
3. Click "Palletize All" to run

LOP processes all items and creates the pallets. A results summary appears showing what was created.

The Assignment Algorithm

Palletize All uses a Best-Fit Decreasing (BFD) algorithm with several intelligent enhancements:

Step 1 — Group Together

Items that belong to the same assembly or group (items sharing a Group ID or Tree Instance ID) are kept together on the same pallet type. This ensures that related items — such as the components of a machine, or parts of the same customer order — travel on the same pallet.

If a group of items does not fit on any of the selected pallet types, those items become floor items.

Step 2 — Smart Sorting

Items are sorted by two criteria:

1. Fragile items last — non-fragile items enter the solver first and are placed at the bottom of pallets. Fragile items enter last and end up on top, where they are protected from crushing.
2. Largest items first — among items of the same fragility, larger items are placed first. This produces denser, more stable base layers.

Step 3 — Fit to Smallest Pallet

Each item is assigned to the smallest pallet type that can physically fit it (the item's footprint must be within the pallet's surface area). Items too large for any selected pallet type become floor items.

Step 4 — Spread Whole Layers

In standard palletization, each eligible item family’s whole layers are spread evenly across its pallets; full pallets in the same family differ by at most one layer. The count combines volume against 75% of the pallet type’s stack volume, weight against its payload, and the minimum needed for the whole layers.

Height, payload, product top-load and pallet stack-weight limits apply. A partial layer goes on a separate pallet; a family short of a whole layer starts with one pallet build. Fragile, non-stackable, STEP, cylinder and vertical-only or horizontal-only items go to the mixed-pallet pool.

Step 5 — Build Each Pallet

Each pallet uses Best Fit with no layer rotation. Units that do not fit go to the leftover pool; the pool fills mixed pallets of the largest selected type one after another. Units that fit no pallet become floor items.

Results Summary

After Palletize All completes, a summary shows:

• Total pallets created — how many pallets were generated
• Full pallets — pallets where all assigned items were placed
• Partial pallets — pallets where some items could not fit
• Floor items — items that could not be palletized (too large, or no pallet type selected)

The counts are honest: if some units could not be placed, the summary says so with a warning rather than silently dropping them.

Unpalletize All

To remove all pallets and return items to the floor:

1. Open the ⋯ overflow menu in the Items Panel header and select "Unpalletize All"
2. All unlocked pallets are removed in a single instant step and their items return to the unplaced items list
3. Locked pallets are preserved — unlock them first if you want to remove them too
4. The plan score refreshes automatically — no re-solve or manual recompute is needed

Per-Item Pallet Overrides

By default, Palletize All assigns items to pallet types automatically using the BFD algorithm. When you have unpalletized items to assign, the dialog offers an "Item Assignments" section — expand it if you need specific items on specific pallets.

For each item, you can select:

• Auto — let the algorithm decide (default)
• A specific pallet type — force this item onto the selected pallet type
• Floor — exclude from palletization, place directly on the container floor

This is useful when certain products must travel on a particular pallet type for customer requirements or handling reasons.

Pallet Stacking Validation

Quick Plan, Smart Plan and Maximum Fill apply the same static pallet-pair rule and reject a pair that fails it. A level top is not required: contact area, stability and load-bearing capacity determine support.

The upper pallet’s center of gravity must stay at least 50 mm inside the convex hull of its contact area along both horizontal axes. A pallet bridging two stacks shares its load between supports using static balance. An item in a pallet below carries its own column plus the share of every pallet or loose unit standing on that pallet, each share split by static balance; a loose unit standing on a loaded pallet is checked for that load only. Racks are not judged as pallets in this rule; a rack standing on a loaded pallet counts as a loose unit.

Known bottom-board layouts are used when both the type code and platform match; GMA follows the NWPCA layout. Other pallets use the full footprint. These checks assess static stacking without simulating transport forces.

Performance

Palletize All solves multiple pallets concurrently for faster results. A plan with many pallets will complete significantly faster than solving each pallet one at a time.

Your active pallet type selections are saved to your account and sync across all your devices — you do not need to re-select your preferred pallet types on each computer.

When to Use Palletize All vs. Manual

Next Steps

• Manual Palletization — build individual pallets with full control
• Packing Patterns — how Column, Interlock, Pinwheel, and Best Fit work
• Managing Pallets — edit, lock, reorder, and delete pallets after creation