Looking up pallet in the dictionary and you read "support for goods or freight". Abuse is a term often associated with pallets; it’s no surprise since they are the most often used as support for all different t varieties of freight worldwide. Oftentimes pallets are kept even though their usefulness and construction are well beyond their prime. Since new pallets cost money, old outdated pallets often continue their life in the fleet. Old and outdated pallets have a tendency to lose their freight, causing it to fall to the floor during their use. The costliness of freight and equipment damage is always present in this situation as is the potential for harm to an employee in the form or injury or even death.

Recognize these important safety tips in case you are working with a palletized load:

• The development of a pallet inspection program should be the first goal. If any weakness is discovered, the pallet should be marked as unfit for use until it can be fixed – or throw away if it can’t be fixed. Using this method can assist with the reduction of costs related to employee safety, reputation of the company and product or equipment damage.

• Remember to start off by balancing your load on the forklift forks – an off balance load is no good. The probability of an off center pallet falling to the ground is greater than a centered load, especially navigating turns and ramps.

• Take a few moments to secure any loose items on the pallet along with any straps, if there are any. Before putting the pallet into the storage system make sure to complete the previous step, as it aides in safer, easier retrieval.

• When stacking multiple pallets, the operator must be very careful. The key to safety here is a balanced stack – not leaning at all. For safety’s sake, make sure the bottom most pallets are in excellent condition – they support the stack. The number 1 way to avoid other goods or people from getting damaged or hurt is to keep the stacks stable and prevent them from toppling over. Setting a max height for pallet stacks is highly advisable. Enforcement of this measure could be achieved by painting a wall mark at such a maximum.

• Forklifts and pallets all have load limits that must be followed. The operator has the responsibility for knowing the load limits of the equipment – and not exceeding them. Exceeding the load limit has dangerous consequences – including the hydraulic system’s failure, which can result in the forklift falling over.

• It will be easier to ensure compliance to load limits if all storage systems (balconies, racks, mezzanines, etc.) are clearly marked with load limits. Without exception, these rules must always be followed.

• Protecting the operator from falling objects can be done by making sure the forklifts overhead cage or screen is in place. The safety cage protects against objects that may have been placed or stored high but not properly secured, causing them to fall towards the operator.

• All pallets are different – and some vary significantly in quality of craftsmanship and materials. Considering the upfront costs of a pallet against the hidden costs incurred from using poor quality pallets is important, and recommended. The purchase of a new high quality pallet is often justified by the hidden costs of a poor quality one. Unhappy customers, inventory write-offs, physical damage, equipment damage and human safety constitute just a few of those unwritten costs.

Time, money and damage can all be saved by keeping proactive measures in mind when working with a forklift. Time and effort spent reloading pallets is a detriment to productivity. An effective, proactive warehouse pallet safety program has the potential to save lives and prevent injury – it’s most important outcome.