How to Fine-Tune Your Pallet Stacking Techniques in 2023

Organisation is crucial in any business, from the smallest shop to the biggest warehouse. Where warehouses, picking and packing are concerned, pallets play a pivotal role, and the way you stack and configure your pallets can make a big difference in the efficiency of your organisation. In this article, we’re going to look at the best, most effective pallet stacking techniques. 

Firstly, let’s run through the different pallet stacking styles available to you. There are three main techniques; block, tapered stacks, and the pinwheel format. They all have their benefits but it’s important that you ensure the stacking method is right for the product you are stacking. 


Blocking is laying your packages on top of one another in a neat format, where they slot together easily – picture a wider Jenga stack, but without the instability. You can take boxes off the top, but certain boxes may be removed from other levels of the stack providing the balance is correct. 


This consists of layers of four items, placed perpendicular to one another to create the illusion of – you guessed it – a pinwheel. Of course, they can only be stacked in this fashion if they are done so in accordance with the width of the pallet, so be sure to arrange them properly. 

Tapered stacking

If the ‘block’ method is similar to how bricks are laid – then the tapered stacking method is a more linear format, with packages stacked on top of each other so that from the side, the small gaps between each package form a uniform, grid-like pattern. 

Things to Remember

Make sure that your pallet stacking method suits the material you are stacking – for soft packages, the pinwheel method may be better suited to coping with the uneven surfaces of each package. Standard, cubed boxes will benefit from the tapered method, and rectangular boxes suit the block method as it allows for the boxes to be turned 90 degrees to fit on the pallet. 

Don’t let your stacks thin out towards the top – if they start to take a pyramid style shape, try to reorganise to make it neater and save space. Similarly, make sure that any stack is not overhanging the edges of the pallet.

These simple tips can help you stack your pallets in a much more organised manner, reducing the risk of accidents or issues that may result in stock wastage or injuries to personnel. 

Rack Storage Systems are proud to provide the highest quality pallet racking for customers around the UK. Our expert team are able to advise you on what would work best for you, and once you’ve chosen your racking system, you’ll benefit from our swift delivery and first-rate customer service. For more information, please get in touch with us today

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