Pallets and corrugated boxes are ubiquitous in the global supply chain. However, the interactions that exist between the boxes and pallet are ignored during the pallet design process resulting in an over design of pallet performance and the waste of raw materials. The goal of this research is to understand how pallet performance is affected by headspace, box size, and base design across multiple support conditions using block class wooden pallets. Headspace and base design had no effect on pallet deflection for the experimental weights used throughout testing. The effect of box size was significant on pallet deflection across multiple support conditions. The effect was greatest for lower stiffness pallets and low stiffness support conditions (RAW) with up to a 50% reduction in pallet deflection observed by switching from small to large boxes on a very low stiffness pallet. Evaluation of pressure mat data showed an increase in the redistribution of pressure away from the center of the pallet and towards the supports as box size increased. The redistribution of pressure towards the supports is known as load bridging and validates the observed reduction in pallet deflection as a function of box size. The results indicate that incorporating the effect of packages into current pallet design practices could result more effective and cheaper pallet designs. / Master of Science / Transportation and storage of material goods at a national and international level is an integral part of our economy with pallets and corrugated boxes making up the majority of packaging materials. Currently, the interactions that exist between the boxes and pallet are ignored during pallet design resulting in an over design of pallet performance and a waste of raw materials. Understanding the interactions that exist in a unit load is important in optimizing pallet performance, reducing the amount of raw materials used, and ultimately reducing cost. This research project is specifically focused on the interactions between corrugated boxes and block class wooden pallets. The effect of headspace (the gap between the products and the top of the box) and box size was investigated as a function of pallet stiffness, support condition, and bottom deck design. Both pallet deflection and the pressure distribution on the top surface of the pallet were examined to evaluate pallet performance. It was found that headspace does not have an effect on pallet deflection unless the weight of the unit load exceeds 3,500 lbs. for small boxes and 1,750 lbs. for large boxes. Base design showed no significant effect on pallet deflection for all of the support conditions evaluated. The effect of box size had a major effect on the deflection of the pallet. Large boxes showed the greatest change especially when lower stiffness pallets were used. Increasing the box size can reduce the deflection of the pallet as much as 50% which means that pallets supporting larger boxes could support much more weight than currently estimated. Evaluation of pressure mat data showed that when the size of the boxes increased, more pressure is distributed towards the supports. More pressure is applied to the pallet section on the top of the supports; therefore, less pressure is available to cause pallet bending. This finding validates the observed reduction in pallet deflection as a function of box size. The obtained results help pallet designers to incorporate the interactions between the packages and the pallet into their design process which will allow them to reduce the amount material used for pallet.

Currently, pallets are designed assuming that the load is distributed evenly on the top of the pallet. When pallets are loaded with packages such as corrugated boxes or returnable plastic containers, due to their physical shape, packages, are not capable of deforming freely with the pallet and a bridging phenomenon occurs. During this load bridging phenomenon, a portion of the vertical forces are redistributed as horizontal forces which causes the redistribution of the vertical compression stresses on the pallet towards the support. As a result, the deflection of the pallet can decrease and the load capacity of the pallet can increase significantly. The second chapter of this paper investigates the effect of package content on pallet deflection. The study concluded that package content did not have a significant effect on pallet deflection within the boundary conditions of the experiment. The third part of this paper considers how a specific pallet characteristic could affect the way a corrugated box performs. Standard box design procedures include adjustments of estimated compression strength for relative humidity, overhang on pallets, vibration, and alignment of boxes. However, there is no adjustment factor for pallet stiffness. The objective of the study described in this thesis is to find an answer for how the compression strength of a box is affected by pallet stiffness and top deckboard twist. The study concluded that the pallet stiffness and top deckboard twist do not have an effect on the compression strength of the box until less than 12% of the area box is supported. / Master of Science / Within the United States alone, there are more than 2 billion pallets in service daily. These pallets transport and store a wide variety of products. There are many factors that could effect the performance of a pallet, and it is still unknown which design factors and possible package interactions will or will not effect pallet performance. The first objective of this thesis is to investigate the effect of package content on pallet deflection. The study concludes that the package content does not have an effect on pallet deflection. With about 1300 manufacturing plants that produce corrugated in the Unites States and Canada, the industry alone provides $26 billion to economies. Corrugated paperboard boxes are used daily for distribution and packaging, allowing products to easily and safely travel the globe. A majority of the time, these boxes are transported and stored on wooden pallets. Currently, there is no safety factor for box design that takes pallet stiffness into consideration. The second objective of this thesis is to investigate the effect of top deckboard twist on box compression strength. The results from the study concluded that the pallet stiffness and top deckboard twist do not have an effect on the compression strength of the box until less than 12% of the area box is supported.

Pallets are the foundation of unit loads and supply chains. They provide a way to store and transport products in an efficient manner. The load capacity of pallets greatly depends on the type of packages carried by the pallet; however, current pallet design methods do not consider the effect of packages on the load carrying capacity of the pallet. This results in excessive use of materials which reduces the sustainability of unit loads, drives costs up, and creates issues for people in the supply chain. The objective of this study was to investigate the effect of a corrugated box's size and head space on pallet deflection and stress distribution on the top of the pallet as a function of pallet stiffness across multiple pallet support conditions. Data analysis identified that box size had a significant effect on the deflection of the pallet. This effect was only significant for warehouse racking across the width and length support conditions. As much as a 53% reduction in pallet deflection was observed for high stiffness pallets supporting corrugated boxes with 25.4 mm headspace when the size was increased from small to large. Meanwhile, no significant effect of box size was found for other supports. The effect of headspace was significant in some scenarios but inconsistent thus more investigation with a larger sample size is recommended. In addition, redistribution of vertical compression stresses towards the supports was observed as a function of the increasing box size. The increased concentration of compression stresses on top of the supports and the resulting lower pallet deflection could significantly increase the actual load carrying capacity of some pallet designs. / Master of Science / Pallets are the foundation of unit loads and supply chains. They provide a way to store and transport products in an efficient manner. The load capacity of pallets greatly depends on the type of packages carried by the pallet; however, current pallet design methods do not consider the effect of packages on the load carrying capacity of the pallet. This results in excessive use of materials which reduces the sustainability of unit loads, drives costs up, and creates issues for people in the supply chain. The objective of this study was to investigate the effect of a corrugated box’s size and head space on pallet deflection and stress distribution on the top of the pallet as a function of pallet stiffness across multiple pallet support conditions. The data from the study identified that box size does have an effect on the deflection of the pallet but, it was only found to be significant for the warehouse racking supports. The highest reduction in pallet deflection was 53% on the high stiffness pallets carrying corrugated boxes with 25.4 mm of headspace as the boxes increased in size. The other support conditions showed no significant effect of the box size. Headspace showed some significant effect in some conditions but was found inconsistent, therefore an investigation with a larger sample size is recommended. In addition, the redistribution of vertical compression stresses towards the supports was observed as a function of increasing box size. This increase in stress on the supports resulted in lower pallet deflection that could significantly increase the actual load carrying capacity of some pallet designs.

The global supply chain has been built on the material handling capabilities provided by the use of pallets and corrugated boxes. Current pallet design methodologies frequently underestimate the load carrying capacity of pallets by assuming they will only carry uniformly distributed, flexible payloads. But, by considering the effect of various payload characteristics and their interactions during the pallet design process, the structure of pallets can be optimized. This, in turn, will reduce the material consumption required to support the pallet industry. In order to understand the mechanical interactions between stacked boxes and pallet decks, and how these interactions affect the bending moment of pallets, a finite element model was developed and validated. The model developed was two-dimensional, nonlinear and implicitly dynamic. It allowed for evaluations of the effects of different payload configurations on the pallet bending response. The model accurately predicted the deflection of the pallet segment and the movement of the packages for each scenario simulated. The second phase of the study characterized the effects, significant factors, and interactions influencing load bridging on unit loads. It provided a clear understanding of the load bridging effect and how it can be successfully included during the unit load design process. It was concluded that pallet yield strength could be increased by over 60% when accounting for the load bridging effect. To provide a more efficient and cost-effective solution, a surrogate model was developed using a Gaussian Process regression. A detailed analysis of the payloads' effects on pallet deflection was conducted. Four factors were identified as generating significant influence: the number of columns in the unit load, the height of the payload, the friction coefficient of the payload's contact with the pallet deck, and the contact friction between the packages. Additionally, it was identified that complex interactions exist between these significant factors, so they must always be considered. / Doctor of Philosophy / Pallets are a key element of an efficient global supply chain. Most products that are transported are commonly packaged in corrugated boxes and handled by stacking these boxes on pallets. Currently, pallet design methods do not take into consideration the product that is being carried, instead using generic flexible loads for the determination of the pallet's load carrying capacity. In practice, most pallets carry discrete loads, such as corrugated boxes. It has been proven that a pallet, when carrying certain types of packages, can have increased performance compared to the design's estimated load carrying capacity. This is caused by the load redistribution across the pallet deck through an effect known as load bridging. Being able to incorporate the load bridging effect on pallet performance during the design process can allow for the optimization of pallets for specific uses and the reduction in costs and in material consumption. Historically, this effect has been evaluated through physical testing, but that is a slow and cumbersome process that does not allow control of all of the variables for the development of a general model. This research study developed a computer simulation model of a simplified unit load to demonstrate and replicate the load bridging effect. Additionally, a surrogate model was developed in order to conduct a detailed analysis of the main factors and their interactions. These models provide pallet designers an efficient method to use to identify opportunities to modify the unit load's characteristics and improve pallet performance for specific conditions of use.

In the supply chain there are three components: transportation method, the pallet, and the packaging. Traditionally, there has been a poor understanding of the way that pallet design can impact the supply chain. There are historical studies that illustrate the importance of investigating how box stacking pattern, unit load type, unit load size, and containment can impact the pallet's performance. However, there have been no studies that have investigated the impact of drums and plastic pails on pallet performance. The goal of the current research study was to investigate how plastic pails and drums affect pallet bending and the distribution of the pressure on the top surface of the pallet. The investigation was conducted using four different support conditions commonly found in warehouses: racking across the width and length, single stacking, and double stacking. The results of the investigation indicated that for most support conditions, loading the pallet with plastic pails or drums results in a significant reduction in deflection when compared to a uniformly distributed load. The maximum observed reduction in pallet deflection was 85% when testing with drums in the double stack condition and 89% when testing with plastic pails in the single stack condition. The large reductions in deflection could indicate that the pallets were over-designed for the unit load that they were supporting. Pressure mat distribution images collected during the experiment display a load bridging effect where the stress of the drums and pails are redistributed to the supported sides of the pallet. The data also show that drums made of different materials distribute the pressure onto the pallet in a significantly different manner. / Master of Science / Wood pallets are crucial to the supply chain that delivers the goods and objects that sustain our economy. Every product order or product that is seen in stores was sent through the supply chain. The supply chain is made up of three major interacting components, the material handling system, the packaging, and the pallet. By further understanding the interaction between these components, pallet and packaging designers can better utilize materials and maximize the efficiency of the supply chain. There is a need to understand how different types of packages interact with the pallet to effectively design pallets and to potentially reduce costs and material usage. Historical studies focused on investigating how corrugated boxes affect pallet performance. They mainly focused on the effect of corrugated box size, flute type, stretch wrapping and containment, and the influences that pallet design have on pallet performance. Past studies identified that packages on the top of the pallet could create a bridging between the packages that can reduce the stresses on the pallet and consequently increase its load capacity. By using this load bridging effect for their advantage, pallet designers can design pallets that are safer, cheaper, and be more environmentally friendly since current wood pallets are designed under the assumption of a uniformly distributed, rather than bridged, load. The goal of the current study was to investigate how the load bridging effect created by pails and drum affects the deflection of the pallet in the floor stacked loading condition. The investigation was conducted using four different support conditions commonly found in warehouses such as racking across the length, racking across the width, single stacking, and double stacking. The results of the investigation indicated that for most investigated support conditions, the interaction between pails and drums causes an increase in load bridging which significantly reduces the bending of the pallet. The reductions reached a maximum of 85% when testing with drums in the double stack condition and 89% when testing with plastic pails in the single stack condition. The large reductions in deflection could indicate that the pallets were over-designed for the unit load that they were supporting.