Damaged pallets can be called the “invisible killer” in the production process, which not only lowers productivity and increases operating costs, but also is usually associated with improper forklift operation. Over time, pallets and their repair costs continue to rise, and profit margins are gradually squeezed. Although there are various forms of pallet damage, forklift operator error is undoubtedly the most common cause.

In line with the development of industry standards, most of the pallet damage problems can be properly resolved by standardizing forklift operation procedures and strengthening employee training. The following suggestions to reduce pallet damage are worth referring to.

1. Slow down

Reducing speed is a key to reducing the risk of forklift damage and is the cornerstone of many techniques. Reducing speed buys the forklift operator more reaction time to handle the pallet more properly, avoiding mistakes such as short forks and improperly set tine spacing. In addition, slowing down prevents collisions between the gantry, tines or other parts of the lift and the pallet and its load. Reduce hasty operation, gentle use of forklifts, but also to extend the service life of the forklift itself, can be said to be a multi-purpose.

2. Accurate Pallet Selection

Pallet capacity is affected by a number of factors, and even small differences in materials, dimensions and structural layout can result in very different load carrying capacities. Overloaded or incorrectly selected pallets are susceptible to breakage, cracking or splintering, especially if the forklift is not operated properly.

Weight distribution is also a key consideration in choosing the right pallet. Even if a pallet carries the correct amount of weight, if it is not evenly distributed, its performance will be affected. Uneven weight distribution can cause the pallet to be stressed in a direction it was not designed for, which can lead to failure. The Pallet Design System (PDS) ensures that the pallet is loaded correctly and performs as intended.

3. Complete fork removal before turning

Damage to the longitudinal beam is a very destructive type of damage to a pallet. Longitudinal beams are the key component that holds the pallet in place, and when they fail, the capacity of the pallet is dramatically reduced. This type of damage usually occurs when the forklift driver releases the load too early and turns, causing the fork tines to impact the longitudinal beam, resulting in strain and damage. Therefore, forklift drivers must make sure that the tines are completely withdrawn from the pallet before turning.

4. Refuse to tow and operate in a standardized manner

“Towing” a pallet, i.e. pushing the pallet to slide along the ground, is not a desirable behavior. The pallet is not designed to be pushed along the ground, and forced dragging will subject it to undue lateral stresses and damage its load-bearing capacity. Also, dragging can cause physical damage to the pallet components, weakening them and increasing the risk of failure.

5. Eliminate the use of short-forked pallets

Short-forking means that the forklift tines are not fully inserted into the pallet before lifting the load. Ensure that the front of the forklift truck door frame is as close to the pallet and load as possible and that the end of the pallet rests on the tips of the tines. The pallet is designed to support the weight of the load, which requires the tines to be fully inserted. Incomplete insertion of the fork tines can put additional stress on the pallet deck and nails, increasing the likelihood of pallet failure or damage. In addition, pallets are more likely to slip and fall when short-forked, especially during rushed operations.

6. Proper Use of Pallet Spacers

Fork tines should be inserted easily and evenly into the pallet and should not come in contact with any part of the pallet until the load is lifted. If the spacing is not set correctly, the fork tines may strike the longitudinal beams, causing damage and affecting the performance of the pallet. Ensuring that the tines do not interfere with intermediate or external pallet supports will extend the life of the pallet. It is also a good idea to use pallets with beveled beams to guide the tines into the pallet.

7. Spread the Forks Early to Spread the Load

Before lifting a pallet, the forklift tines should be placed as far apart as possible to spread the load. If the forklift is equipped with automatic fork tine spacing adjustment (such as pitch forks), the fork tines can be spread after they enter the pallet; if manual adjustment is required, it should be completed before entering the pallet. Proper fork tine spacing will stabilize the pallet and load and reduce the amount of stress placed on the pallet.

Following these practical tips can effectively reduce the damage rate of forklift pallets, save costs for enterprises, improve efficiency, and help enterprises move forward steadily in the fierce market competition.