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The Magic of Pallets

HughPickens.com writes Jacob Hodes writes in Cabinet Magazine that there are approximately two billion wooden shipping pallets in the holds of tractor-trailers in the United States transporting Honey Nut Cheerios and oysters and penicillin and just about any other product you can think of. According to Hodes the magic of pallets is the magic of abstraction. "Take any object you like, pile it onto a pallet, and it becomes, simply, a "unit load"—standardized, cubical, and ideally suited to being scooped up by the tines of a forklift. This allows your Cheerios and your oysters to be whisked through the supply chain with great efficiency; the gains are so impressive, in fact, that many experts consider the pallet to be the most important materials-handling innovation of the twentieth century." Although the technology was in place by the mid-1920s, pallets didn't see widespread adoption until World War II, when the challenge of keeping eight million G.I.s supplied—"the most enormous single task of distribution ever accomplished anywhere," according to one historian—gave new urgency to the science of materials handling. "The pallet really made it possible for us to fight a war on two fronts the way that we did." It would have been impossible to supply military forces in both the European and Pacific theaters if logistics operations had been limited to manual labor and hand-loading cargo.

To get a sense of the productivity gains that were achieved, consider the time it took to unload a boxcar before the advent of pallets. "According to an article in a 1931 railway trade magazine, three days were required to unload a boxcar containing 13,000 cases of unpalletized canned goods. When the same amount of goods was loaded into the boxcar on pallets or skids, the identical task took only four hours." Pallets, of course, are merely one cog in the global machine for moving things and while shipping containers have had their due, the humble pallet is arguably "the single most important object in the global economy."

8 of 250 comments (clear)

  1. Like many inventions ... by BarbaraHudson · · Score: 5, Insightful

    Like many inventions, it's obvious with hind-sight. But palettes also required improvements elsewhere, such as factory floors that were reasonably level and solid, capable of supporting stacked palettes, and eventually racking.

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    1. Re:Like many inventions ... by Computershack · · Score: 5, Informative

      It takes time to build pallets. It takes time to break apart, resort, and rebuild pallets. It costs money to repair and replace the pallets themselves. Pallets require extra ceiling space to actually pick them up and put them into a truck or container, resulting in wasted volume in that truck or container. The logistics industry is quickly moving away from pallets for everything but long term storage.

      Actual truck driver here. No they're not or at least in Europe they're not. You can load a pallet onto a truck with just a couple of inches clearance, enough for the skids on the pallet not to slide along the floor. What actually determines pallet height and therefore wasted space in a truck is the racking at the warehouses. Its the spacing between the shelving on the racking. Rented pallets is the model used the most with Chep being the largest player in the world. Most large companies won't accept goods unless they're on Chep pallets, that's how well they're built and how well designed the rental system is. You don't need to worry about the time it takes to build pallets or repair them because Chep take care of that. You merely send one of your trucks in to a Chep factory en-route back to load up 300 pallets or get Chep to deliver them and collect the damaged ones.

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    2. Re:Like many inventions ... by Computershack · · Score: 5, Informative
      Thank you for demonstrating you have no fucking clue about haulage or logistics. The vast majority of goods are transported palletised. You can unload 3,000 cases of palletised goods far faster than two or three people stuck in the back of a semi-trailer can put them on a conveyer belt. It takes a warehouse 20 minutes to unload a full 26 pallet load semi-trailer, it takes 2hrs to unload 1500 cases on a conveyer belt. I should know, I've spent 20 years as a trucker.

      Please stop commenting about something you don't know shit about, you're just embarrassing yourself.

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  2. Re:More job loss by Kohath · · Score: 5, Funny

    Solution: a pallet tax. The money from the tax will go to ... well, nevermind where the money goes. We need to tax these job-killing pallets now!

  3. Re:slashvertisement by PPH · · Score: 5, Funny

    Personally, I find either brand to be unpalatable.

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  4. Re:4 Days? by choprboy · · Score: 5, Insightful

    While the parent may be off a bit, the quoted article times are ridiculous unless you are counting "man hours" including transport to/from the railcar and stacking on a shelf. It is absurb to think that a single boxcar would be staged on a busy warehouse spur for 3 days of loading or that a modern palletised boxcar takes 3-4 hours to unload with a forklift/pallet jack (it takes about 30min or so).

    Long ago I worked a Target dock unloading trucks by hand. Depending on the store volume and the season, that would mean unloading between 3000 and 10,000 cases from 53' trailers each night, 5 to 6 nights a week. Unlike Walmart and some other stores, Target merchandise all came stacked in the truck except for a few bulk items (kitty litter/etc.), it is individually bulk-broke from the warehouse to restock each item depending on the previous days sales. (A large case count on an incoming truck always made us groan as it probably meant lots of deodorant/hair products which come in small 6 count cases.)

    A typical 6000 case trailer, including setup and teardown time, would take approximately 2 hours to unload. 2 people in the trailer placing boxes on a conveyor, 4 to 6 people pulling/sorting boxes off the conveyor and on to pallets for storarge or delivery to the floor. If you extrapolate that to a 13,000 piece count you get roughly 24 man-hours, or "3 days" assuming a single 8-hour shift.

    Likewise, I also worked a different warehouse job forklift loading 53' trailers. If all of your stock is pre-staged on the dock it takes about 15min to load a trailer. If you are pulling every pallet from the racks and transporting it to the trailer individually it will take 1 to 1-1/2 hours plus. Again, extrapolating that to an 85' boxcar you get roughly 3-4 hours.

    So.... the only way you get the articles quoted loading/unloading times is you are counting man-hours including transport/, not literal time as is implied.

  5. Re:Pallet comments by denzacar · · Score: 5, Funny

    I find your joke unpalletable.

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  6. Re:Pallet ecosystem by theycallmeB · · Score: 5, Informative

    Don't forget plastic stretch wrap: until they get wrapped up tight many pallet load are too dangerous to move more than a few feet and impossible to move over the bumps of a dock plate. Rope, tape, cargo nets and other options can kinda work but the modern pallet freight system would slog down without cheap, disposable (and recyclable) plastic wrap. (Aside: I have been witness to what happens when a Walmart store runs out of pallet wrap. It is... awkward.)