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The Almighty Buck Technology

The Magic of Pallets 250

HughPickens.com writes Jacob Hodes writes in Cabinet Magazine that there are approximately two billion wooden shipping pallets in the holds of tractor-trailers in the United States transporting Honey Nut Cheerios and oysters and penicillin and just about any other product you can think of. According to Hodes the magic of pallets is the magic of abstraction. "Take any object you like, pile it onto a pallet, and it becomes, simply, a "unit load"—standardized, cubical, and ideally suited to being scooped up by the tines of a forklift. This allows your Cheerios and your oysters to be whisked through the supply chain with great efficiency; the gains are so impressive, in fact, that many experts consider the pallet to be the most important materials-handling innovation of the twentieth century." Although the technology was in place by the mid-1920s, pallets didn't see widespread adoption until World War II, when the challenge of keeping eight million G.I.s supplied—"the most enormous single task of distribution ever accomplished anywhere," according to one historian—gave new urgency to the science of materials handling. "The pallet really made it possible for us to fight a war on two fronts the way that we did." It would have been impossible to supply military forces in both the European and Pacific theaters if logistics operations had been limited to manual labor and hand-loading cargo.

To get a sense of the productivity gains that were achieved, consider the time it took to unload a boxcar before the advent of pallets. "According to an article in a 1931 railway trade magazine, three days were required to unload a boxcar containing 13,000 cases of unpalletized canned goods. When the same amount of goods was loaded into the boxcar on pallets or skids, the identical task took only four hours." Pallets, of course, are merely one cog in the global machine for moving things and while shipping containers have had their due, the humble pallet is arguably "the single most important object in the global economy."
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The Magic of Pallets

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  • by BarbaraHudson ( 3785311 ) <barbara.jane.hud ... minus physicist> on Sunday December 21, 2014 @06:33PM (#48649117) Journal
    Like many inventions, it's obvious with hind-sight. But palettes also required improvements elsewhere, such as factory floors that were reasonably level and solid, capable of supporting stacked palettes, and eventually racking.
    • Re: (Score:2, Funny)

      by Anonymous Coward

      Yes, I liked how palettes went from 16 colors on the Commodore 64, to 4096 on the original Amiga, then we had True Color and 24 bit and all that jazz.

      But what does this have to do with shipping pallets? Your comment has left a bad taste in my palate.

    • And forklifts. The invention actually consists of two parts to be really successful - the second part being the forklift or pallet jack. Moving pallets by hand sucks.
      • by Euler ( 31942 )

        Yeah exactly, which came first? The pallet is virtually useless without the fork. I wonder if the fork jack was invented first, but people got tired of the lower row of boxes in every stack being punctured. :p Some innovative person somewhere thought about it and realized the need for a frame to support the stack of boxes over the forks. But how did they decide to call it a pallet?

        • by Jeremi ( 14640 )

          . But how did they decide to call it a pallet?

          I'm not sure about how that was decided, but I will note that an older definition [thefreedictionary.com] of the word was "A temporary bed made from [straw] bedding arranged on the floor, especially for a child". Perhaps they envisioned the wooden frames as temporary beds for products to rest on?

    • by cascadingstylesheet ( 140919 ) on Sunday December 21, 2014 @09:25PM (#48649821) Journal

      Like many inventions, it's obvious with hind-sight. But palettes also required improvements elsewhere, such as factory floors that were reasonably level and solid, capable of supporting stacked palettes, and eventually racking.

      Very true.

      "Humans passing things hand over hand" is actually a pretty cool "invention", when you think about it. Amazingly adaptable.

      We sure couldn't get pallets down the hatch of a submarine. Instead, everyone lined up, from the pier down to where we were stacking the cans.

      • by Deadstick ( 535032 ) on Sunday December 21, 2014 @10:10PM (#48649977)

        Instead, everyone lined up, from the pier down to where we were stacking the cans.

        Time was, surface vessels got their fuel the same way: all the enlisted plus the ensigns passing sacks of coal.

        • by Chris Mattern ( 191822 ) on Monday December 22, 2014 @05:17AM (#48650957)

          Time was, surface vessels got their fuel the same way: all the enlisted plus the ensigns passing sacks of coal.

          In the US Navy, they made a contest of it, too, starboard watch against port watch. If you made the ship list enough (because you filled the coal bunkers on your side so much faster), your side got extra leave.

      • Interesting. I bet you also needed to employ some interesting storage techniques because of the cramped quarters.

        Reminds me of this scene [youtube.com].

        • Interesting. I bet you also needed to employ some interesting storage techniques because of the cramped quarters.

          Reminds me of this scene [youtube.com].

          You bet correctly.

          For example, supplies like flour and lard came in tall rectangular "cans" (metal containers with a pry-off lid). We would strap those to the deckplates and then just walk on top of them.

  • by turkeydance ( 1266624 ) on Sunday December 21, 2014 @06:36PM (#48649127)
    that can be seen from Space!
    • Used to have bonfires at the California beaches. After too many people lost a foot from stepping on smoldering pallets covered with sand, the state made open bonfires illegal and the department for parks built fire rings to burn wood in designated areas. You could not longer burn a whole stack of pallets. If you broke the pallets down and remove the nails, you could tee-pee the wood inside the fire ring to burn.
      • by Immerman ( 2627577 ) on Sunday December 21, 2014 @07:36PM (#48649387)

        >If you broke the pallets down and remove the nails...

        You're doing it wrong - break the pallets down by breaking them - a maul or sledgehammer will usually do the job nicely. Then burn them and drag a magnet through the ashes to collect the nails. Why go through all the effort of removing the nails when you're about to remove the wood?

        Of course given the number or lazy, irresponsible assholes in the world who would just leave the nails to wreak havoc on the next people to use the area I can't say I'd be surprised if the law required pre-extraction.

        • Why go through all the effort of removing the nails when you're about to remove the wood?

          If you pull the nails out properly, you can reuse them again. Something I learned from my father. He always had a coffee can of odd nails he pulled from old pallets and other wooden debris. That's something he learned from his father during and after WWII to avoid wasting hard-to-get material.

          • This is a terrible idea. First off, the time invested in carefully pulling nails of almost any sort quickly eclipses the cost of new nails. Second, the cheap wire nails (often clipped head nails) may work decently when fired from a pneumatic nail gun, but, unless you're quite competent with a hammer, good luck actually driving them into a 2x4.
            • by mengel ( 13619 )
              Actually if you know how to do it, pallets are easy [youtube.com] to pull apart and de-nail [youtube.com].

              And you get usable lumber and nails to make stuff out of.

              Burning them is a waste.

              • Pallets should be used until they are no longer functional and then recycled for the organic matter and iron. Disassembling then for lumber and nails is inefficient and a waste.
                • One of the big advantages of pallets over boxes or containers is that they are cheap enough that shipping them back isn't something you need to worry about in many cases. Yes, if there's a load (or a regular truck) going back to where they need to be loaded it's often better to ship back and re-use, but if they are delivering something and there's no load going back any time soon, they are cheap and easy enough to take apart that they can be discarded and used for other purposes.

              • by __aaclcg7560 ( 824291 ) on Sunday December 21, 2014 @10:50PM (#48650111)

                And you get usable lumber and nails to make stuff out of.

                That's what my father did after he retired to a trailer park. One neighbor gave him old pallets to break down because the county dump charges a small fortune to dispose of them. He gave the usable wood and nails to a neighbor to build chicken coops and bird houses for sale. The unusable wood goes into a neighbor's wood chipper to make compost. The unusable nails are taken down to the recycling center. A win-win situation for everyone involved.

        • Many nails are made from steel with too high of carbon content, and are not magnetic.
        • Then burn them and drag a magnet through the ashes to collect the nails.

          Where I live (Pacific Northwest) you can't drag a magnet through sand on a beach - It becomes covered in the sand grains that are ferrous.

  • The Box (Score:4, Informative)

    by Anonymous Coward on Sunday December 21, 2014 @06:37PM (#48649137)

    "The Box: How the Shipping Container Made the World Smaller and the World Economy Bigger is a non-fiction book by Marc Levinson charting the historic rise of the intermodal container (shipping container) and how it changed the economic landscape of the global economy."

    http://en.wikipedia.org/wiki/The_Box:_How_the_Shipping_Container_Made_the_World_Smaller_and_the_World_Economy_Bigger

  • More job loss (Score:5, Insightful)

    by ArsonSmith ( 13997 ) on Sunday December 21, 2014 @06:38PM (#48649139) Journal

    Think of the dock works who lost their jobs due to this "marvelous" invention. It's this efficiency and automation we have to fight against or nobody will have a job again. /sarcasm

    • by Kohath ( 38547 ) on Sunday December 21, 2014 @06:45PM (#48649179)

      Solution: a pallet tax. The money from the tax will go to ... well, nevermind where the money goes. We need to tax these job-killing pallets now!

    • Re: (Score:2, Funny)

      by Opportunist ( 166417 )

      Ok, who left the door open and let the union guy in?

    • Pretty sure lots of the people that would have come back from the war to do that work, wound up getting an education, and becoming lawyers and bureaucrats.

       

    • Think of how expensive everything would be if all the pallets didn't exist requiring extra workers at the ports...

      • Re:More job loss (Score:4, Insightful)

        by roman_mir ( 125474 ) on Sunday December 21, 2014 @07:48PM (#48649429) Homepage Journal

        yes, that is what the parent post said and was specific to use sarcasm tag for people who he knew wouldn't get it to accent the point that ignorant luddits should in principle be against every labour saving innovation that people come up with, not just the most obvious (machines, computers, robots), but everything we do. Everything we invent and innovate is a labour saving device somehow. To stop that would be to give up on the idea of humans changing environment to improve our circumstances. Luddits want to stop progress, be it computers and robots or pesticides and pallets. The parent comment was pointing it out, not complaining about it.

    • by PPH ( 736903 )

      Give them a rifle and send them to the front lines.

  • by wisnoskij ( 1206448 ) on Sunday December 21, 2014 @06:45PM (#48649183) Homepage
    I have hand loaded many of those standard sized shipping containers myself, with un-palleted materials, it takes two guys like 3-4 hours. And there is no reason that loading would be any faster than unloading.
    • its the union regulations that slow it down.

    • Re:4 Days? (Score:4, Funny)

      by oodaloop ( 1229816 ) on Sunday December 21, 2014 @06:59PM (#48649237)
      You can unload 13,000 cases of unpalletized canned goods in four hours, the same amount of time it takes anyone else with pallets? That's pretty fucking amazing, I must say.
      • Re:4 Days? (Score:5, Informative)

        by BarbaraHudson ( 3785311 ) <barbara.jane.hud ... minus physicist> on Sunday December 21, 2014 @07:16PM (#48649313) Journal

        I have hand loaded many of those standard sized shipping containers myself, with un-palleted materials, it takes two guys like 3-4 hours. And there is no reason that loading would be any faster than unloading.

        You can unload 13,000 cases of unpalletized canned goods in four hours, the same amount of time it takes anyone else with pallets? That's pretty fucking amazing, I must say.

        A boxcars-worth (86' - 13,000 cases) of anything won't fit into a standard shipping container (20') or even a double-length container (40').

      • Well I would question the 4 hours to remove a load of pallets from a container. They are only two wide, and what like 8 deep? You should be able to do that in like 30 minutes.
        • You can put about 30 Pallets of goods into a standard semi trailer. I know, because I unload at least 3 of them a week, and it takes 5 guys about 20 minutes, and thats only because our arrangement is a bit retarded, with a better floor plan, it could be done in 15 minutes or less. Like other responders have noted however, a standard boxcar is much larger.
        • Well the calculation would assume they were not using a motorized pallet jack, since it was comparing the 1920s

          But even then, it depends on how heavy the pallets are.

      • Re:4 Days? (Score:5, Insightful)

        by choprboy ( 155926 ) on Sunday December 21, 2014 @08:06PM (#48649495) Homepage

        While the parent may be off a bit, the quoted article times are ridiculous unless you are counting "man hours" including transport to/from the railcar and stacking on a shelf. It is absurb to think that a single boxcar would be staged on a busy warehouse spur for 3 days of loading or that a modern palletised boxcar takes 3-4 hours to unload with a forklift/pallet jack (it takes about 30min or so).

        Long ago I worked a Target dock unloading trucks by hand. Depending on the store volume and the season, that would mean unloading between 3000 and 10,000 cases from 53' trailers each night, 5 to 6 nights a week. Unlike Walmart and some other stores, Target merchandise all came stacked in the truck except for a few bulk items (kitty litter/etc.), it is individually bulk-broke from the warehouse to restock each item depending on the previous days sales. (A large case count on an incoming truck always made us groan as it probably meant lots of deodorant/hair products which come in small 6 count cases.)

        A typical 6000 case trailer, including setup and teardown time, would take approximately 2 hours to unload. 2 people in the trailer placing boxes on a conveyor, 4 to 6 people pulling/sorting boxes off the conveyor and on to pallets for storarge or delivery to the floor. If you extrapolate that to a 13,000 piece count you get roughly 24 man-hours, or "3 days" assuming a single 8-hour shift.

        Likewise, I also worked a different warehouse job forklift loading 53' trailers. If all of your stock is pre-staged on the dock it takes about 15min to load a trailer. If you are pulling every pallet from the racks and transporting it to the trailer individually it will take 1 to 1-1/2 hours plus. Again, extrapolating that to an 85' boxcar you get roughly 3-4 hours.

        So.... the only way you get the articles quoted loading/unloading times is you are counting man-hours including transport/, not literal time as is implied.

  • Pallet ecosystem (Score:5, Insightful)

    by Livius ( 318358 ) on Sunday December 21, 2014 @06:49PM (#48649195)

    People understood the usefulness of the concept when the first pallets were built nearly a century ago, but a pallet isn't helpful without lift trucks, cranes, etc. That's why adoption started slow and accelerated over time.

    • Re:Pallet ecosystem (Score:5, Informative)

      by theycallmeB ( 606963 ) on Sunday December 21, 2014 @08:46PM (#48649645)
      Don't forget plastic stretch wrap: until they get wrapped up tight many pallet load are too dangerous to move more than a few feet and impossible to move over the bumps of a dock plate. Rope, tape, cargo nets and other options can kinda work but the modern pallet freight system would slog down without cheap, disposable (and recyclable) plastic wrap. (Aside: I have been witness to what happens when a Walmart store runs out of pallet wrap. It is... awkward.)
  • slashvertisement (Score:4, Informative)

    by Noah Haders ( 3621429 ) on Sunday December 21, 2014 @06:51PM (#48649207)

    there are approximately two billion wooden shipping pallets in the holds of tractor-trailers in the United States transporting Honey Nut Cheerios

  • by Namarrgon ( 105036 ) on Sunday December 21, 2014 @06:59PM (#48649235) Homepage

    Arguably, pallets are just accessories for the machine that actually does the work. I'd like to see people unload a boxcar full of pallets by hand.

  • by __aaclcg7560 ( 824291 ) on Sunday December 21, 2014 @07:05PM (#48649259)

    I did a PC refresh job with another guy at a local hospital where the IT department stored old equipment inside a chain-link cage inside a warehouse-style storage room. This was also where construction debris from other parts of the hospital were dumped here.The place was a disaster area -- and our new work area.

    Since our first PC shipment wasn't expected for another three days, we spent that time cleaning up. Finding a pallet-sized box with low walls, we hauled out ten pallets of construction debris to the dumpster on the first day. We sorted and organized equipment to pallets on the second day. And, finally, we hauled everything out of the cage to sweep and mop the floor on the third day. Thereafter, people complained they couldn't find anything because we stacked everything on pallets. :/

    We eventually deployed 750 PC's and 1,500 monitors. Every two weeks we got 10+ pallets of equipment that filled our work area. A week of unboxing, a week of deploying. This became the rhythm of the project. All the old equipment (minus the labeled hard drives that we kept in case we needed to pull data) got boxed up on pallets for the recycler. On the final day of the project, we left the cage clean and empty than it was before.

    Later on I cleaned up an IT storage room filled with old equipment that no one have seen the floor in over eight years. That took six weeks of my spare time between tasks to clean up. Most of the old equipment ended up on pallets for the recycler. After I got the room completely empty, I had facility come in to mop and wax the floor.

  • by Irate Engineer ( 2814313 ) on Sunday December 21, 2014 @07:07PM (#48649279)

    Depending on where and how the wood in the pallets is processed, pallets can host invasive wood-boring insects. Locally we're having problems with the Asian longhorn beetle which is believed to have been introduced to Massachusetts via shipping pallets and crates. A lot of port cities and major shipping centers have seen outbreaks.

    There are plastic and metal pallet systems that should be used if shipping long distances.

    • I've seen recyclable cardboard pallets that are good for moderate weight loads. They don't have the same life cycle as a wooden pallet, but they can be discarded with the cardboard for regular recycling.
      • Also plastic. Possibly not quite as recyclable as cardboard, but I suspect the service life would be much longer.

    • by Strider- ( 39683 ) on Sunday December 21, 2014 @07:28PM (#48649361)

      This is why there are now standards for what wood can be shipped internationally. All wood packaging entering the United States (Pallets, Cable spools, crates, etc...) is supposed to be fumigated and treated to avoid this. This is one of the things that import inspections actually do catch.

  • by Beardo the Bearded ( 321478 ) on Sunday December 21, 2014 @07:31PM (#48649375)

    This comment was on a pallet.

    But the longshoremen were on break. Union rules, sorry.

  • by Earthquake Retrofit ( 1372207 ) on Sunday December 21, 2014 @07:38PM (#48649391) Journal
    have long sung the praises of the lowly pallet which protects our stuff from the occasional 'water event' as we call them in the Northwest.
  • Whereas the Microsoft Ribbon is an abomination.
  • Just for the record barrels were probably equally revolutionary in their time. And the ability for a person to roll them before machinery was quite an advantage.

  • Summary says:

    the challenge of keeping eight million G.I.s supplied—"the most enormous single task of distribution ever accomplished anywhere,"

    I wonder how USSR managed it, since they have an even greater amount of soldier deployed

  • alt.fan.pallets

  • While am no fan of Hugh Pickens, I do love pallets and logistics in general, and like this article.

    As my dad is a truck driver, as a kid I would go with him on trips and see the inner workings of the industry that literally keeps the country rolling. Most trucks would take on empty pallets in exchange for full ones they offloaded. But the trucks did not always go back to the same location that they made the pickup at. I asked him once what happens to all the extra pallets that end up at the receiving end? H

    • Interestingly enough the article mentions iGPS. I saw a good number of their pallets (they have branding on them) at Costco the other day.

  • I work for a large annual convention, and at our most recent event we took our first baby steps into using pallets. We got a bunch of plastic pallets and a pallet jack to move them.

    For us, it's about doing our load-in and load-out at the venue quickly. Before, we'd have one or two trucks doing the rounds between our storage space and the venue. The trucks would arrive, and then we'd load everything into the trucks one piece at a time (using boxes, at least), and then the trucks would go off and we'd sit on

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