Distribution centre technology provider, Lucas Systems, recently announced its Dynamic Pallet Builder technologies which offer a dynamic and automated way for workers to build better pallets with optimal efficiency and tailored to specific warehouse needs.
The sophisticated software solution – which sifts through a myriad of requirements and data points – makes thousands of calculations per minute looking across relevant warehouse operations to determine the appropriate trade-offs needed to optimally pick, group, sequence and stack items on one or more pallets at a time. Pallet-building recommendations consider a wide variety of variables including product size, weight, stacking rules, shipping regulations, worker travel distance, safety, route order, order priorities and more.
Dynamic pallet building technology is reshaping how warehouses approach one of the most fundamental and often overlooked tasks in order fulfilment. In fact, according to Packaging Digest, up to 11% of loads arriving at a distribution centre show some case damage, with the average around 2%.
By intelligently factoring in product characteristics, dynamic systems build safer, more stable pallets that minimise damage and reduce safety risks. Stable loads not only protect workers and equipment, but also cut down on costly returns, rework, and shipment delays caused by product breakage or shifting during transport.
Beyond improving load quality, dynamic pallet builders deliver measurable operational gains. These systems reduce unnecessary travel and eliminate inefficient pick paths, saving labour and energy while increasing throughput. Workers spend less time rearranging pallets or compensating for suboptimal stacking, and more time completing tasks efficiently. Perhaps most importantly, dynamic pallet building adapts to changing conditions—whether that’s seasonal order spikes, shifting product mixes, or evolving warehouse rules. By continuously optimising in real time, these tools help operations stay agile and cost-effective in the face of constant change.
“It’s constantly and dynamically optimising throughout the day,” says Lucas Systems CMO Ken Ramoutar.
The software solution, which seamlessly integrates with a wide variety of warehouse management systems, is unique because it’s highly configurable, aligning with a company’s specific operations and priorities.
Dynamic Pallet Builder’s ‘dynamic’ attribute helps warehouse operators stay as agile and responsive as possible which leads to not only smarter-built pallets but also overall productivity gains and reduced damage.
Lucas Systems says warehouse agility is paramount for today’s complex logistics environments, and that’s why the company has invested in a number of dynamic-driven technologies over the last year.
Known for its decades of experience with voice-directed picking, Lucas Systems says its Dynamic Pallet Builder is transformative due to its connection to picking operations.
“Smarter pallet building also means smarter picking. Building better pallets can have a significant impact on reducing damage, minimising worker travel, reducing transportation mileage and improving productivity,” says Ramoutar.
Lucas Systems customer, Veritable Vegetable, uses Dynamic Pallet Builder to better optimise its delivery routes. The California-based organic produce distribution company uses a two-part voice-directed picking process to split its pallets. In doing so, its pallet-building logic is tailored to precisely match its trucks and delivery operations.
“This personalised approach provides optimal efficiencies for us, and it also gives our customers more flexibility when placing orders. Both are extremely important,” says Veritable Vegetable Owner and CEO Mary Jane Evans.
Lucas Systems helps companies create a dynamic warehouse, enabling distribution centres to compete more effectively under ever-changing market conditions. We harness the power of data with AI, Machine Learning, speech recognition, and optimisation models to provide operational agility and improved distribution centre performance. Unlike fixed or mechanical automation, Lucas delivers a flexible, software-based approach, that can adapt to future business needs cost effectively.
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