Why Automated Warehouses Need Better Pallets

The warehouse automation market is growing rapidly. From automated storage and retrieval systems (AS/RS) to robotic palletizers to autonomous mobile robots (AMRs), technology is transforming how warehouses operate. But there's a catch that technology vendors don't always mention: automated systems are only as reliable as the pallets they handle.

The Problem

Manual warehouse operations are forgiving. A worker on a forklift can adjust for a pallet that's slightly oversized, warped, or has a protruding nail. Automated systems can't.

Common pallet-related automation failures include:

Each failure event costs downtime, maintenance intervention, and potentially damaged products.

The Quality Requirements

Automated warehouses typically require pallets that meet these specifications:

Used Pallets Can Qualify

Here's the good news: automation-grade pallets don't have to be new. A properly graded and inspected used pallet in Grade A condition can meet all of the above requirements. The key is the inspection process.

At Stockton Pallet Co., our Grade A pallets go through an inspection specifically designed to catch the issues that cause automation problems. We measure dimensions, check flatness, verify board integrity, and ensure no protrusions exist. For customers running automated warehouses, we can provide pallets that are tagged and tracked for quality consistency.

The Cost-Benefit

Yes, automation-grade used pallets cost more than standard used pallets. But they cost significantly less than new pallets — and far less than the downtime and maintenance costs of feeding substandard pallets into automated systems.

Consider: a single conveyor jam that takes 30 minutes to clear might cost $500-$2,000 in lost productivity, depending on your operation. If that jam is caused by a $5 pallet, the economics of paying a few dollars more for quality are crystal clear.

Working With Your Supplier

If you're running or planning an automated warehouse, have a detailed conversation with your pallet supplier about your specifications. Provide them with the dimensional tolerances and quality requirements from your equipment vendor. A good supplier will work with you to ensure every pallet delivered meets those specifications.

The era of "any pallet will do" is over for automated operations. But with the right supplier partnership, getting the quality you need doesn't have to break the budget.