Palletize All

Palletize All automatically assigns every unpalletized item in your plan to pallets. Instead of building each pallet manually, LOP distributes all items across the smallest number of pallets needed — using your active pallet types, respecting weight and size limits, and balancing the load evenly.

How to Use It

1. Click "Palletize All" in the Items Panel header
2. In the dialog that opens, configure:
   • Pallet types — select which of your active pallet types to use (at least one required)
   • Clear existing — whether to remove current unlocked pallets before reassigning (locked pallets are always preserved)
   • Packing pattern — choose the arrangement strategy for all pallets
   • Layer rotation — optionally rotate layers for stability
   • Item Assignments (optional) — expand this section to assign specific items to specific pallet types, or mark items as "Floor" to exclude them from palletization. Default is "Auto" (LOP assigns automatically)
3. Click "Palletize" 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 — Load Balancing

Rather than filling one pallet completely before starting the next, LOP estimates how many pallets of each type are needed and distributes items evenly by weight across them. This produces pallets with similar total weights — easier to handle, safer to stack, and better balanced in the container.

The estimate uses both volume (at 75% target fill) and weight (max payload) to determine the pallet count, then uses a greedy lightest-bucket algorithm to distribute items.

Step 5 — Solve Each Pallet

Each balanced group of items is solved independently using the selected packing pattern and layer rotation settings. Items that cannot be placed on their assigned pallet move to a leftover pool and are reassigned to additional pallets if possible.

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)

Unpalletize All

To remove all pallets and return items to the floor:

1. Click "Unpalletize All" in the Items Panel
2. All unlocked pallets are removed and their items return to the unplaced items list
3. Locked pallets are preserved — unlock them first if you want to remove them too

Per-Item Pallet Overrides

By default, Palletize All assigns items to pallet types automatically using the BFD algorithm. If you need specific items on specific pallets, expand the "Item Assignments" section in the dialog.

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

After pallets are created, LOP checks whether each pallet has a flat, even top layer. Pallets with uneven tops show a "⚠ Uneven Top" warning badge. This means the pallet may not safely support another pallet stacked on top of it during transport.

To resolve uneven top warnings, try a different packing pattern or adjust the items assigned to that pallet.

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