Smarter Pallets.
Faster Fulfillment.
Greater Efficiency.

Built Specifically for Your Unique Requirements

Balancing speed, stability, and varied product types under tight deadlines makes pallet building highly complex, with even minor errors resulting in significant safety and efficiency impacts.

Lucas Systems’ Dynamic Pallet Builder transforms traditional palletization by leveraging AI and real-time data to dynamically optimize every pallet built. Based on order specifics, product attributes, and warehouse layout, it’s specific to each customer’s unique needs.

Unlike static, rule-based approaches, Dynamic Pallet Builder creates more efficient pick paths and pallet configurations that reduce labor, enhance safety, and accelerate throughput, all while seamlessly integrating with your WMS and existing warehouse tools.

What are bad pallets costing you?

11%

Of loads could be arriving at the distribution center showing damage. With the average around 2%. Most of the damage is caused by compression according to Packinging Digest

Pallet Builder animation

Why Dynamic Pallet Builder is a Game-Changer

  • Cost Savings – Reduce labor-intensive activities and energy use by minimizing travel distance and streamlining pick paths. The result? Lower operational costs across the board.

  • Safety – Building pallets with precision using product weight, fragility, and stackability ensures stable loads, reduces strain on material handling equipment, and minimizes the risk of tipping or collapse, protecting workers from injury and maintaining a safer warehouse environment.

  • Damage Reduction – Properly accounting for how products can be stacked and supported helps prevent crush damage, shifting in transit, and product breakage, lowering the likelihood of costly returns, rework, and shipment delays.

  • Productivity Gains – Eliminate unnecessary steps and reduce the time spent rearranging pallets. With optimized pick sequences and product groupings, workers complete tasks faster, with less effort and higher throughput.

  • Built for Flexibility – Whether it’s peak season or slow periods, or your order profiles, rules or processes change, dynamic algorithms adapt to these fluctuations and complexities, keeping operations consistently optimized and responsive.

Case Study: Veritable Vegetable

Demonstrating Innovation and Sustainability in Produce Distribution

“Lucas’s Dynamic Pallet Builder helps our team handle complex orders with precision and care. It intelligently accounts for weight, size, container type, and truck dimensions—whether we’re building full or less-than-pallet loads. That means more secure, efficient shipments, less rework, and better support for our team. It’s one more way we’re investing in smart tools to move fresh, organic produce with integrity and reliability.”

Mary Jane Evans, Owner and CEO, Veritable Vegetable

Solving the Key Challenges of Palletization

VV warehouse workers building pallet

Product Characteristics
Dynamic Pallet Builder accounts for critical attributes like weight, fragility, and stackability—arranging items in a way that ensures safe transport, easy unloading, and maximum pallet efficiency.

Order Priority and Timing
Prioritize urgent orders in real time, ensuring time-sensitive shipments are picked and processed first—without disrupting the overall flow. This prevents bottlenecks and keeps your fulfillment schedule on track.

Travel Distance and Pick Sequencing
By intelligently sequencing picks and optimizing placement on the pallet, the Dynamic Pallet Builder reduces worker travel time and improves overall picking speed. Labor costs drop while productivity and warehouse space utilization increase.

Frequently Asked Questions: 

Dynamic Pallet Builder is a solution that uses complex algorithms to generate optimized pallet configurations in seconds, determining how products should be arranged on a pallet based on real-world constraints like weight, size, fragility, and stackability. Rather than relying on worker judgment under time pressure, it automatically calculates the safest, most space-efficient build – accounting for customer-specific rules, shipping regulations, and order priority – to produce stable, secure loads without slowing down the picking process. 

Building pallets dynamically improves efficiency by optimizing picking sequences and grouping products logically so workers complete picks faster with less travel and less effort. It eliminates time spent reorganizing pallets or making judgment calls about placement. By minimizing unnecessary worker travel and creating smarter order groupings, it increases throughput without adding headcount. Lucas customers using Best Pallet Matching have achieved 15–30% travel savings from batch optimization and over $5 million in annual labor cost savings. 

The system builds pallets with the receiving store's needs in mind, grouping products by aisle, department, or delivery sequence so store teams can unload and stock directly without re-sorting. It factors in product characteristics like weight, cube, and category while respecting customer-defined rules for how items should be grouped. Best Pallet Matching also enables picking for multiple stores simultaneously on double or triple pallet jacks, with each store's pallet built to its specifications while maintaining warehouse efficiency. 

Up to 11% of loads arriving at distribution centers show case damage, with most caused by compression from poor stacking. Dynamic Pallet Builder accounts for product weight, fragility, and stackability to ensure heavier, denser items form the base while lighter or fragile items sit on top. The 3D allocation algorithm detects when a stack would be unstable and spills items to another pallet rather than placing an unsafe load, reducing crush damage, shifting in transit, and costly returns. 

Lucas EthOS seamlessly integrates with Warehouse Management Systems and other platforms, receiving order data, product attributes, and location information through standard interfaces. It analyzes this data in real time to create optimized batches and pallet configurations, then directs workers through voice-guided execution via Jennifer. The system accommodates any number of warehouse- and customer-specific rules without requiring WMS changes, operating as an intelligent optimization layer between the host system and the warehouse floor. 

Industries with diverse product profiles and complex delivery requirements benefit most, particularly grocery and food service (temperature zones, heavy liquids, fragile items), beverage distribution (high-weight cases requiring stable builds), wholesale distribution (mixed SKU pallets for multiple store formats), and retail fulfillment (store-ready pallet requirements). Any operation that picks mixed-product pallets under time pressure, where balancing speed, stability, and store-specific requirements is critical can gain significant value from dynamic pallet optimization. 

Set a New Standard in Fulfillment

Let’s turn your distribution operation into a competitive advantage, together.