{"id":5802,"date":"2026-06-08T15:55:43","date_gmt":"2026-06-08T13:55:43","guid":{"rendered":"https:\/\/libra-partners.pl\/2026\/06\/08\/pallets-for-automated-storage-and-retrieval-systems-as-rs\/"},"modified":"2026-06-16T15:00:46","modified_gmt":"2026-06-16T13:00:46","slug":"pallets-for-automated-storage-and-retrieval-systems-as-rs","status":"publish","type":"post","link":"https:\/\/libra-partners.pl\/en\/2026\/06\/08\/pallets-for-automated-storage-and-retrieval-systems-as-rs\/","title":{"rendered":"Pallets for automated storage and retrieval systems (AS\/RS)"},"content":{"rendered":"\t\t
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Pallets for automated storage and retrieval systems (AS\/RS)<\/p>\n

A pallet in an automated warehouse has just one key task: never to bring the line to a halt. Any deviation in dimensions, weight or rigidity\u2014even by a single millimetre\u2014will sooner or later trigger a system alarm, cause the stacker crane to stop and result in costly machine maintenance. <\/p>\n

What is an automated storage and retrieval system (AS\/RS)?<\/b><\/p>\n

Automated storage and retrieval systems (AS\/RS) are state-of-the-art logistics environments in which autonomous stacker cranes, shuttle systems or miniload systems \u2013 controlled directly via warehouse management systems (WMS) and PLCs \u2013 are responsible for the transport, storage and retrieval of goods.<\/p>\n

For these systems, the pallet serves as the direct \u2018mechanical-logistical interface\u2019. It must therefore have absolutely reproducible dimensions, a constant weight and unchanging structural rigidity, as the entire automated system operates with tolerances in the millimetre range. Unlike a traditional high-bay warehouse, which is operated by forklift drivers, there is no room for even the slightest deviation from the norm in AS\/RS systems. A single warped board, a broken skid or a protruding nail can block the forks of the stacker crane or the optical sensor, thereby paralysing the operation of the entire distribution centre. <\/p>\n

What is the most important factor when it comes to pallets for automation?<\/b><\/p>\n

We can identify five key features that a transport vehicle must have in warehouse automation:<\/p>\n

1. Absolute dimensional repeatability<\/p>\n

In automated warehouses, it is essential that every pallet has identical dimensions (the Euro standard: 1200 \u00d7 800 \u00d7 144 mm). Stacker cranes and shuttle trolleys are designed for a fixed format. Plastic pallets, produced using injection moulding, guarantee identical dimensions for each unit, eliminating sensor reading errors and the risk of collisions. <\/p>\n

2. No nails, splinters or loose parts<\/p>\n

Protruding nails or splinters of wood are the most common cause of mechanical damage to roller and belt conveyors. What is more, small splinters and wood dust contaminate photoelectric cells and safety sensors. Control systems interpret them as obstacles on the route, which generates false alarms and forces a manual restart of the line. A plastic pallet is completely uniform and free of metal components. <\/p>\n

3. High structural rigidity<\/p>\n

A pallet designed for automated handling must not bend or twist under the weight of the cargo \u2013 particularly when stored on cantilever racks. Excessive deflection shifts the load\u2019s centre of gravity, which means that advanced vision systems and automated grippers may incorrectly identify the pallet\u2019s position, rejecting it to the error station. <\/p>\n

4. Clean, uniform and stable runners<\/p>\n

Any defects in the runners, unevenness or damp patches on wooden pallets cause slippage, increase rolling resistance on the rollers and result in uneven loading of the electric drives. The smooth, consistent surface of the plastic pallet\u2019s runners ensures smooth movement and stable operation of the entire transport system. <\/p>\n

5. Controlled and consistent kerb weight<\/p>\n

The algorithms that control warehouse automation are based on precise calculations of the permissible weight: load weight + pallet weight. The weight of traditional wooden pallets can vary by as much as several kilograms, depending on their moisture content. Plastic pallets have a constant tare weight, which facilitates the calibration of system scales and overload protection mechanisms. <\/p>\n

Shelf load capacity certified to ISO 8611<\/b><\/p>\n

In AS\/RS warehouses, the key parameter is the racking load capacity, i.e. the ability of the load-bearing structure to rest safely on the crossbeams under maximum load without exceeding the permissible deflection.<\/p>\n

When selecting a medium for automation, one must not rely solely on marketing claims. It is essential to have certified parameters obtained from laboratory tests conducted in accordance with the international standard ISO 8611. Only objective destructive and load tests in accordance with ISO 8611<\/b> guarantee that a pallet placed in an automated racking system will maintain the required rigidity and will not cause a system failure. <\/p>\n

Wood vs plastic in AS\/RS warehouses \u2013 A summary of the differences<\/b><\/p>\n