Are You Running Out of Pallets Too Often?
Running short on pallets doesn’t always happen all at once. More often, there are small warning signs that your ordering schedule isn’t keeping up with demand.
If your team is constantly scrambling, delaying shipments, or borrowing pallets from other departments, it may be time to rethink how often you reorder. Here are some of the most common signs you’re not bringing in pallets often enough—and what to do instead.
You’re Frequently Running Out at the Worst Time
If pallet shortages always seem to happen during peak shipping days, promotions, or seasonal surges, your reorder cycle is probably too long.
When you wait until inventory is low before placing an order, you leave no room for unexpected volume increases or delivery delays.
Consider moving to weekly deliveries or a scheduled replenishment plan. Smaller, more frequent shipments help keep inventory steady and reduce the risk of last-minute shortages.
Employees Are Hunting for Pallets
If forklift drivers, warehouse staff, or receiving teams spend time looking for usable pallets, that’s a hidden productivity cost.
Even a few minutes per shift adds up when multiple employees are involved. When pallets aren’t readily available, loading slows down, staging areas get cluttered, and workflows become inconsistent.
Set a minimum on-hand pallet level and reorder before you hit it. Many facilities also benefit from vendor-managed inventory (VMI), where your pallet supplier monitors usage and keeps you stocked automatically.
You’re Using Damaged or Low-Quality Pallets Just to Get By
When inventory runs low, teams often start using pallets that should have been repaired or scrapped.
This can lead to:
- Product damage
- Safety risks
- Failed inspections
- Extra handling time
If you’re forced to use whatever is available, it’s a sign your supply isn’t keeping up with demand.
Instead, work with your supplier to create a regular delivery + repair + removal cycle so broken pallets leave as quickly as new ones arrive.
Orders Get Delayed Waiting for Pallets
When shipments can’t go out because there aren’t enough pallets, the real cost goes beyond the pallet itself. Delays can impact customers, carriers, store locations, and production schedules.
If this happens more than occasionally, your ordering frequency likely doesn’t match your actual usage.
Track how many pallets you use per week—not just per month. Many operations find that weekly or bi-weekly deliveries align much better with real demand than large, infrequent orders.
Your Dock Swings Between Too Many and Not Enough
One week you’re overloaded with pallets. The next week you’re short. This unpredictable cycle usually means your ordering schedule isn’t aligned with your flow of goods.
Large, infrequent orders can create storage problems when pallets arrive—and shortages when they run out.
Ask your supplier about scheduled deliveries or vendor-managed inventory, which keeps pallet levels consistent without overloading your space.
You Don’t Know How Many Pallets You Actually Use
If pallet orders are based on habit instead of data, it’s easy to fall behind.
Start tracking:
- Pallets used per week
- Pallets repaired or discarded
- Seasonal volume changes
With accurate usage numbers, your supplier can recommend a delivery schedule that keeps you stocked without overbuying.
A Better Approach
At Rose Pallet, we work with distribution, retail, and warehouse teams to build pallet supply programs that match real-world usage—not guesswork. If your operation is running short more often than it should, it may be time to change how you reorder. Let’s Talk Today!
