Notches

Definition and purpose

A notches pallet is a pallet variant in which controlled recesses or cut‑outs (notches) are made in the pallet stringers, blocks or deck boards. These notches are intentional geometric modifications that provide clearance for forklift tines, pallet jacks, conveyor fingers, automated guided vehicle (AGV) end effectors, or allow pallets to nest or stack compactly. Notches change how forces transfer through the pallet structure and therefore are incorporated to optimize handling, compatibility with equipment, or storage density.

Common configurations

Notches are most frequently applied to:

• Stringer pallets: rectangular or semicircular notches cut in the stringer to provide four‑way entry when full through‑stringer fork pockets are not used.

• Block pallets: notches in blocks or bottom deck boards to permit narrower tine entry or to allow specialized handling fixtures to engage the pallet.

• Deck‑board notches: small recesses in the top or bottom deck boards to clear conveyor rails or to enable secure stacking/nesting.

How and when notches are used

Notches are specified when standard pallet geometries do not meet operational requirements.

Typical use cases include:

• Four‑way entry conversion: converting a two‑way stringer pallet to have limited four‑way entry by cutting notches into stringers to accept fork tines from the sides without weakening the entire stringer.

• Compatibility with handling equipment: enabling entry of hand pallet jacks, narrow‑tine forklifts, or AGV forks where the standard fork pocket spacing does not align with the pallet stringers or blocks.

• Nesting and space saving: producing notches that allow identical pallets to nest or interlock for lower empty return volume.

• Conveyor and automation integration: providing clearance for conveyor rails, transfer fingers, or robotic grippers used in automated warehouses and cross‑dock facilities.

• Custom load interfaces: accommodating product geometry (e.g., drums, crates) so the pallet supports and secures the load effectively without interfering with handling devices.

Design considerations and technical implications



Notching affects the pallet’s structural behavior.

Key technical aspects include:

• Load path alteration: Removing material reduces bending resistance and shear capacity at the notch location; designs must ensure remaining cross‑section sustains expected static and dynamic loads.

• Stress concentration: Notches create stress risers. Radiused corners and smooth transitions reduce peak stresses compared with sharp corners.

• Material and thickness selection: Softer or thinner components require more conservative notch sizes or reinforcement (e.g., metal plates, additional deck boards).

• Equipment interface tolerances: Notch dimensions must match fork tine width, thickness and approach angle, allowing sufficient clearance for safe engagement but not so large as to permit excessive movement.

• Environmental and lifecycle factors: Repeated loading, moisture cycling (for wood pallets), and wear at notch edges can reduce longevity; coatings, edge banding or alternative materials (plastic, metal) can mitigate degradation.

Manufacturing methods

Typical processes for creating notches depend on material and production volume. For wooden pallets, notches are cut using saws or routers on stringers or deck boards during assembly. For plastic and composite pallets, molds incorporate notch geometry or CNC machining is used post‑molding. Metal pallets are cut, stamped or laser‑cut to introduce notches. Precision and repeatability are important for automated handling compatibility.

Standards and specification practices

While specific notch dimensions are driven by customer equipment, good practice is to document:

• Notch location relative to pallet datum points (e.g., edge distances, centerlines).

• Notch dimensions and tolerances (width, depth, corner radius).

• Material grade, thickness and any reinforcement details.

• Load ratings and test results: static and dynamic load tests, cycle testing for automated systems.

Examples in industry

Grocery and beverage distribution often uses notched pallets to allow forklifts or pallet jacks to access loads from multiple directions in confined retail backrooms. Manufacturers who employ in‑plant conveyors and robotic palletizers specify notches to clear conveyor rails and permit indexing. Returnable pallets used in closed‑loop automotive supply chains may include stacking notches that let pallets nest tightly to reduce return transport costs.

Best practices for implementation

• Perform a requirements analysis: measure fork tine dimensions, carriage geometry and any automation tooling before specifying notch size and location.

• Use radiused transitions: specify corner radii to minimize stress concentration and prolong component life.

• Validate with physical testing: prototype notched pallets and run static, dynamic and fatigue tests representative of operational cycles.

• Document tolerances: create clear drawings and tolerance bands so manufacturing matches handling equipment consistently.

• Consider reinforcement: where notches significantly reduce section modulus, add metal plates, thicker members or alternate materials to preserve load capacity.

• Plan maintenance and inspection: include notch edge wear checks in routine inspections and replace pallets with excessive damage.

Common mistakes and pitfalls

• Over‑notching: Removing too much material without compensating for strength loss leads to premature failure under load.

• Poor tolerance control: Incompatible or imprecise notch dimensions can prevent safe entry by forklifts or cause jamming in automation systems.

• Ignoring dynamic effects: Designing only for static loads while neglecting impact, racking or repeated coupling cycles reduces service life.

• Not accounting for wear: Notch edges abrade over time; lack of edge protection accelerates deterioration, especially for wooden pallets.

• Incompatible racking use: Some racking systems require full stringer support; notched stringers may be unsuitable for direct racking without verification.

Summary

Notches pallets are a pragmatic design modification used to reconcile pallet geometry with handling equipment and storage needs. When engineered correctly they improve handling flexibility, enable automation integration and reduce transport inefficiencies. Because notches change structural behavior, disciplined specification, prototyping and testing are essential to maintain safety and longevity in the warehouse and transport environments.