Steel pallets are the sturdiest option in warehousing, making them ideal for both Automated Storage and Retrieval Systems (ASRS) and high-bay warehouses. Heavy-duty steel pallets can support even more weight, but they are heavier than a standard steel pallet.

When designing heavy-duty steel pallets for these specialized warehousing scenarios, here is what we always keep in mind to ensure a reliable and efficient process for our customers:

Using Heavy-Duty Steel Pallets in Highly Automated Warehousing Environments

One of the benefits of heavy-duty steel pallets is the customizability of bases. Steel pallets can be built to fit with whatever automated systems are maneuvering them, whether it’s the Roomba-like robots used in Amazon warehouses or a robotic arm lifting them from underneath. American Manufacturing can design floor plates to lock in or pins that help automated robots sense where the pallet is.

Wood pallets aren’t effective in automated environments because they can easily be broken or grabbed incorrectly by systems designed to move quickly. Customizability is limited and the tolerances won’t be as tight as they can be with steel, meaning you’ll end up investing a lot in finding an automation that can handle wood and slowing down your processes rather than adapting the pallet to the ASRS as you can do with steel.

Pallet Design Tolerances

Most warehousing systems use some form of conveyor system to feed pallets in and out of the facility. When the pallet reaches the automated pick point, it needs to be positioned with high accuracy for where the robotic process will occur — usually within 1/16th of an inch of tolerance. Steel pallets can incorporate pins that set the pick point, signaling to the ASRS when the pallet has reached the pick point and maintaining the tight tolerance.

Reducing Deflection with Steel

Deflection (or bowing) is a common problem with less durable pallet materials like plastic or wood. If you’re using large pallets bearing a lot of weight, wood and plastic pallets can bow easily under heavy or uneven weight distribution. Heavy-duty steel pallets are highly rigid, and we design ours with corrugated decks that increase rigidity without adding additional weight.

Using Heavy-Duty Steel Pallets in High-Bay Storage Environments

Warehouses with high-bay storage environments make great use of vertical space, meaning heavy pallets of materials or products may be stored at very high heights. In these scenarios, pallets must be compatible with the racks on which they are stored. Some high-bay storage environments will use decking to adjust for undersized pallets, but it’s always better to have pallets built to fit perfectly, like custom steel pallets.

While heavy-duty steel pallets are the most durable option, you need to take shelf heights and weight capacity into account before committing to heavier pallet options. Wood pallets have the benefit of being so light that the added weight of a pallet is almost negligible, but they won’t provide the stability and strength of steel. Heavy-duty steel pallets are the heaviest pallet options, so it’s crucial to ensure your weight tolerance can bear them.

Safety Considerations

While they require a higher weight tolerance for racks and lifting equipment, heavy-duty steel pallets provide much more reliable safety in high-bay storage environments. Wood and plastic cannot compete with steel when it comes to durability, increasing the risk of pallets breaking or bending and causing heavy materials to spill down onto the warehouse floor. When these materials are being lifted to such high storage heights, it becomes extremely hazardous to risk them falling.

Bar Code and RFID Considerations

When placing bar codes and RFID labels on pallets for warehouse tracking, we recommend keeping them inside the unit and away from the fork pocket. Wherever the forklift will be making contact with the pallet, it can wear down or rub off stickers or hardware, leading to tracking errors.

Custom Steel Pallets for Every Warehouse

Whether your warehouse makes use of ASRS, has high-bay storage, or faces other unique challenges when it comes to pallet selection, American Manufacturing can customize steel pallets to meet your needs with efficiency and safety in mind. Contact us to discuss upgrading your pallets to steel!