Palletised Storage: Block Stacking

In Block Stacking, loaded pallets are placed directly onto the floor and built up in stacks, in rows. Ideally, any one row of pallets should only contain pallets of the same products to avoid double handling and to simplify stock location records.

The block stacking technique is used with plain palletised loads, pallet converters and similar load protection devices that are used if the load itself is not strong enough or flat enough to permit safe stacking.

When setting out simple block stacking, clearances should incorporate to facilitate fork truck movement. It is good practice to empty a row completely before putting any more stock into that row, and it is important to maintain stock location records to ensure stock discipline.

The technique is suitable where there is limited number of product lines, each of which has a comparatively high stock level.

The advantages of Block Stacking are:

• Lower capital costs;
• No storage equipment needed;
• Good use of area though not necessarily of height;
• Simple to control; and
• Suitable for high throughputs.

The disadvantages of Block Stacking are:

• Limits on stack height which can restrict the use of building height;
• Honeycombing which reduces storage capacity;
• No strict FIFO;
• Free access is only to pallets at the top of each row; and
• Fire risk.