Palletizing might seem simple—but how you build pallets can seriously impact your efficiency, costs, and delivery speed. As SKU counts grow, and orders get more complex, mixed palletizing is more important than ever. Two main methods are used: sequenced and on-the-fly. Here’s a quick breakdown:
Sequenced Palletizing: Organized and Efficient
This method follows a pre-set item order. It’s ideal when you know what’s coming down the line and want to stack smarter based on size, weight, or fragility.
✅ Packs pallets tighter to save space and shipping costs
✅ Improves stability and reduces product damage
✅ Makes tracking and inventory simpler
✅ Keeps labor workflows predictable
Best for: High-volume warehouses, 3PLs, and operations where precision matters.
On-the-Fly Palletizing: Fast and Flexible
Built in real time using AI and vision systems, this method adapts on the spot without a fixed item order.
✅ Handles thousands of SKUs with ease
✅ Great for e-commerce and fast-changing orders
✅ Cuts down on pre-sorting and keeps things moving
Best for: E-comm, high-mix environments, or facilities using mobile robotics.
Which One’s Right for You?
Many operations benefit from using both. At SRSI, we design systems that fit your goals—whether that’s saving space, reducing manual work, or improving order flow.
Further Reading
• Sequenced vs. On-the-Fly Mixed Palletizing – MixedPalletizing.com
• The Science Behind Mixed-Case Robotic Palletizing – Progressive Robotics
• How Mixed Palletizing Improves Logistics Efficiency – ABB Robotics
