As supply chain operators grapple with labor shortages, storage capacity crunch, and competitive pressure to delight customers, interest in Automated Storage and Retrieval Systems (AS/RS) and other forms of warehouse automation continue to surge. Automation can tick all the boxes for companies looking to reduce touch labor, improve storage density, improve accuracy, and increase fulfillment speed.

However, pallet and unit load quality matters to get the most out of your multi-million dollar AS/RS investment. As one AS/RS sales executive noted recently, “Automation loves consistency.” A lack of consistent quality can lead to expensive downtime, with direct costs of thousands of dollars per hour. And that might be the tip of the iceberg when you consider the indirect costs of late shipments, overtime stocking requirements, empty shelves, and a tarnished reputation.

Every stage of the AS/RS process, from induction to retrieval, depends on pallets maintaining their structural integrity. Let’s follow the journey of a palletized load through a typical AS/RS system and explore how various pallet defects can disrupt this automated process.

Step 1: Induction – Entering the System

The system inspects the pallet and load at the induction station for dimensions, alignment, and weight. The most critical factors at this stage are dimensional accuracy and structural integrity. Warped or damaged pallets (e.g., cracked boards or missing nails) can cause misalignment issues and failed induction. Protruding nails may also scrape sensors or conveyors, leading to delays or system malfunctions.

Step 2: Conveyor and Shuttle Transport – Moving to Storage

Once the pallet passes induction, it moves via conveyor or shuttle to storage. Smooth motion is crucial to avoid bottlenecks. Pallet deflection can reduce clearance, causing the pallet to sag and come into contact with conveyor surfaces, leading to jams. However, pallet issues like broken boards or protruding nails are equally disruptive, potentially damaging the machinery or causing system stoppages.

Step 3: Vertical and Horizontal Lifts – Precision in Action

To avoid load instability, the pallet must maintain its structure during vertical or horizontal lifts. Deflection at this stage is less problematic than missing or broken boards, which can result in uneven load handling and potential collapse. This stage relies on the pallet’s ability to handle the load without structural failures, ensuring precise placement in racks.

Step 4: Storage in the Racks – Ensuring Stability

Once the system reaches the correct height, the system inserts the pallet into the racks. Minimal clearance is essential in AS/RS systems, so deflection or warping can cause improper placement. Misaligned or damaged pallets (due to sagging, cracks, or protruding nails) can lead to load instability or future retrieval problems, increasing the likelihood of system disruption and downtime.

Step 5: Retrieval – Getting the Pallet Back Out

In the retrieval stage, structural issues become more apparent. Deflected or damaged pallets may not align properly, causing the system to struggle with lifting or moving the pallet. Broken boards or other damage can lead to jams, retrieval failures, or even load spills, requiring manual intervention and causing costly downtime.

The Impact of Pallet Deflection on AS/RS Downtime

Pallets might seem like an afterthought, but in an AS/RS, even minor disruptions can snowball into significant downtime. A single jam caused by an inconsistent pallet can halt the entire system, impacting productivity, delaying shipments, and requiring expensive repairs. The cost of downtime in an AS/RS is steep: every hour of downtime can cost a company tens of thousands of dollars, not to mention the ripple effects on supply chain operations.

Pallet Best Practices

To minimize the risks associated with pallet deflection and other quality issues, companies need to be proactive about pallet selection and maintenance:

• Invest in High-Quality Pallets: Choose durable, high-quality pallets designed to prevent sagging or warping under heavy loads.
• Ensure Dimensional Accuracy: Pallets must maintain consistent size and shape to avoid misalignment, jams, or malfunctions within the AS/RS system.
• Inspect Pallets: Regularly inspect pallets for signs of deflection, cracks, and other structural issues, and remove damaged pallets from circulation.

AS/RS systems aim to maximize efficiency and precision, but they depend heavily on the integrity of the pallets they handle. Pallet deflection, warped boards, protruding nails, and other defects can lead to system malfunctions, costly downtime, and safety risks. Given the high cost of unplanned AS/RS downtime, ensuring that pallets meet strict quality standards is not just a good practice—it’s a critical operational necessity.

If your AS/RS system isn’t performing to expectations or you are planning to install one, why not talk to PalletOne? We have deep experience helping warehouse operators get the most out of their automation investments and are happy to review your situation.