Picking entire loaded pallets, typical of cross-docking and bulk replenishment.
Detailed Definition
In a full pallet pick the order quantity equals one or more complete pallets of a single SKU, so the pallet moves out as received without being broken down. It is common for large customer orders, for cross-docking where inbound pallets go straight to outbound doors, and for replenishment moves that bring a reserve pallet down to a case pick face. Handling is done with a forklift, reach truck or pallet jack rather than by hand.
Where full pallet picks fit in the order profile
Warehouses usually group order lines into three handling levels: full pallet, full case and split case. Full pallet lines are the cheapest to handle per unit because one lift moves the whole quantity. Orders that are close to a full pallet are sometimes rounded up by the customer's ordering rules so they can ship this way.
Because the pallet leaves intact, the condition of the inbound pallet becomes the condition of the outbound pallet. A damaged base, broken deck board or loose wrap carries straight through to the customer.
Checks before a full pallet ships
- Confirm the pallet type and footprint match the receiver's requirements, since some customers specify pool pallets or a particular grade.
- Re-wrap or re-label if the inbound wrap or labels are damaged.
- Verify the quantity on the pallet matches the order and the shipping label.
- Check that height and weight fit the trailer and the receiver's rack positions.
A frequent error is assuming a manufacturer's pallet is acceptable to every customer. If the receiver requires a different pallet, the load may need to be transferred before shipping.
Related Glossary Terms
Frequently Asked Questions
Is a full pallet pick the same as cross-docking?
No. Cross-docking is a flow strategy in which inbound freight is moved to outbound doors with little or no storage time. Full pallet picking is a handling method in which a complete pallet is selected for an order. Cross-docked freight is often handled as full pallets, but full pallet picks also happen from regular rack storage, for example when a customer orders a pallet quantity of a stored SKU.
Why do some receivers reject full pallets that look fine?
Receivers often have rules on pallet type, footprint, grade, height, labeling and wrapping that are set in their routing guide or vendor manual. A pallet can be structurally sound and still fail those rules, for example if it is a white-wood pallet where a pool pallet is required, if it is too tall for the receiving rack, or if the SSCC label is missing or unreadable. Check the receiver's current requirements before shipping.