Pallet handling processes: from palletising to transport

May 22nd, 2025

From product formation to final shipment, the way goods are packed, compacted and transported has a direct impact on final quality and on the overall profitability of the plant. In this context, automated pallet handling is not an add-on, but a strategic factor.

Below, we analyse in detail the main processes involved in pallet handling, from initial preparation to delivery to the customer, as well as the key machines that optimise each stage.

The importance of efficient pallet management in industrial environments

In industrial sectors such as ceramics, logistics or manufacturing, palletising is not merely the final step of the production cycle, but a critical link between production, storage and transport.

Proper pallet and load management directly affects key aspects:

  • Stability and safety of the finished product: Poorly compacted or unstrapped loads may tip over, suffer damage or be rejected at destination.

  • Operational continuity: Automated systems require a constant and predictable flow. Poor pallet management creates bottlenecks that disrupt production.

  • Cost savings: Reducing pallet usage, packaging materials, labour and unnecessary movements improves profitability.

  • Sustainability: Effective planning reduces waste (film, strapping, wood) and improves energy efficiency.

In addition, efficient management allows products to be prepared for long-term storage or intercontinental transport while maintaining their original quality. This results in fewer returns, higher customer satisfaction and stronger competitive positioning.

1. Pallet wetting: intelligent product preparation

Even before the product leaves the production line, there is a stage that may appear secondary but is decisive in sectors such as ceramics or structural bricks: pallet wetting. This process helps prevent future breakage and improves the surface finish of the final product.

The pallet wetting system is designed to spray water evenly over the pallets and, in some cases, over the stacked products themselves. Its purpose is twofold:

  • Prevent breakage in products made with high-limestone clays, where pre-moistening stabilises chemical reactions caused later by lime content.

  • Improve the appearance of facing bricks or rustic products by avoiding uneven absorption or lime staining.

2. Compaction with rotary press: the basis of stability

Once products are placed on the pallet, stacking alone is not sufficient. Gaps or irregular positioning can cause instability, displacement or breakage during transport. This is where the rotary press comes into play, providing a solid and compact load.

The rotary package press applies controlled vertical pressure to the stacked products, eliminating voids and aligning the pieces. This action offers several benefits:

  • Greater load stability, preventing movement during strapping or transport.

  • Improved compaction, allowing reduced use of film, corner protectors or straps.

  • In some models, package rotation facilitates rearrangement and optimises positioning for subsequent strapping.

3. Strapping and net wrapping: transport safety

After compaction, it is essential to ensure that the load maintains its shape and cohesion at all times. Strapping and net wrapping provide the structural security required to withstand vibration, movement and intensive handling.

Strapping systems apply PET or polypropylene straps around the load, while net wrapping covers it with a flexible mesh. Both systems can operate independently or together, offering key advantages:

  • They can eliminate the need for pallets in some cases, creating self-supporting loads.

  • Automatic tensioners and sensors ensure uniform and durable fastening.

  • Material use is optimised, reducing waste generation.

In many industrial plants, pallet consumption has been reduced by up to 25%, resulting in direct savings of up to €3 per unit and improved logistical sustainability.

4. Package accumulators: flow continuity in logistics

One of the most common bottlenecks in automated processes occurs when finished loads await collection. Package accumulators allow production to continue uninterrupted by efficiently managing outbound flow.

These systems accumulate prepared packages on chain conveyors, enabling forklift operators to collect two or more units at a time without disrupting palletising operations. Their key advantages include:

  • Reduced collection time due to fewer movements.

  • Continuous production flow, independent of internal transport availability.

  • Efficient use of space through multi-level stacking.

The use of accumulators has been shown to reduce operator travel by up to 25%, improving ergonomics and overall plant efficiency.

5. Transport and dispatch: from plant to customer

The final stage of pallet management is transferring the load to the dispatch area or directly onto the truck. Here, conveying systems play a decisive role in maintaining dispatch speed and preventing load damage.

Different internal transport solutions are available, including:

Gantry systems with clamps or forks

  • High-capacity equipment designed to safely handle and move loads.

  • Can be operated via wired control panels, wireless controls or fully autonomous laser-guided systems.

  • These systems can reduce truck loading time by up to one hour per day, a critical advantage in high-dispatch-volume plants.

Pallet feeders

  • Systems that automatically supply empty pallets at the start of the line.

  • Eliminate manual handling, reducing occupational risks and downtime.

The combination of these elements ensures a smooth, safe and efficient process from preparation to truck loading.

Efficient pallet management is far from a minor task in industrial environments. Each stage—from wetting to final transport—plays a key role in product quality, resource optimisation and logistics safety.

Implementing specific solutions such as pallet wetting systems, rotary presses, strapping/net wrapping systems, accumulators and automated gantries enables industrial plants not only to increase productivity but also to enhance competitiveness in increasingly demanding markets.

Investing in intelligent automation is investing in a more agile, safe and profitable process.