Empty pallets are easy to overlook when planning warehouse automation. They do not contain inventory, but they still occupy floor space, require handling, and frequently create unnecessary forklift traffic.

AGV forklifts can automate the collection, transportation, sorting, and return of empty pallets when the workflow is clearly defined.

Why Automate Empty Pallet Movement?

Empty pallets often move through a warehouse repeatedly:

• From receiving or unloading areas to a pallet storage zone

• From picking areas to empty-pallet collection points

• From production-free staging areas to storage

• From shipping areas back to pallet storage

• Between different warehouse zones

Because these movements are repetitive and predictable, they can be suitable for AGV automation.

What Should the Empty-Pallet Workflow Look Like?

A basic workflow can be divided into four stages:

1. Empty pallet becomes available.

2. The system identifies the collection location.

3. An AGV collects and transports the pallet.

4. The AGV delivers it to an assigned return or storage location.

The important point is to define what triggers each stage.

For example, a pallet sensor may detect that a stack has reached a certain condition, or a WMS/WCS task may instruct the AGV to collect pallets from a predefined location.

How Should Empty Pallets Be Stored?

The answer depends on pallet type and warehouse space.

Possible configurations include:

• Single-pallet positions

• Stacked pallet locations

• Dedicated empty-pallet lanes

• Multiple pallet-type zones

• Temporary collection areas

If different pallet dimensions are used, the software and AGV configuration should distinguish them where necessary. A workflow designed for one standardized pallet should not automatically be assumed to work with multiple pallet formats.

How Can AGVs Identify Empty Pallets?

Empty pallet identification can use several methods depending on the warehouse system.

• Predefined task locations

• Barcode identification

• Vision systems

• Presence sensors

• WMS inventory information

• Operator-triggered transport tasks

Not every empty pallet needs an individual identity. In some workflows, the system only needs to know that a pallet is available at a defined collection point.

What Happens When Pallets Are Damaged?

Empty-pallet automation should include an exception process.

A damaged pallet may not be safe for automated handling. Broken boards, missing runners, excessive deformation, or unstable stacking can interfere with fork insertion and load stability.

The warehouse should therefore define a reject location or manual inspection process for pallets that do not meet the handling requirements.

How Does Empty-Pallet Automation Affect High-Bay Warehouses?

In a high-bay warehouse, empty pallets should not unnecessarily occupy valuable automated storage locations.

A better design may use dedicated ground-level collection and return zones while reserving high-value rack positions for inventory pallets.

The AGV fleet can then transport empty pallets between operational areas and the dedicated pallet zone.

How Should Priority Be Managed?

Empty-pallet movements normally have lower urgency than customer shipments or production-critical pallet movements.

The fleet control system can therefore assign different task priorities.

For example:

• Urgent outbound pallet: high priority

• Production-critical pallet: high priority

• Standard putaway: normal priority

• Empty-pallet collection: lower priority

The exact priority rules should reflect the warehouse's actual operating requirements.

What Should Be Measured?

• Empty pallet moves per shift

• Average waiting time for collection

• AGV utilization

• Manual interventions

• Empty-pallet accumulation

• Rejected pallet events

• Traffic generated by empty-pallet movements

These measurements can determine whether empty-pallet automation is actually reducing manual handling rather than simply changing where the work occurs.

What Should You Give an AGV Supplier?

Provide the supplier with:

• Pallet dimensions

• Empty pallet weight

• Maximum stack height

• Number of pallet types

• Collection locations

• Return locations

• Daily and peak movement volumes

• Existing WMS/WCS interfaces

• Areas where manual forklifts currently handle empty pallets

With this information, the supplier can determine whether empty-pallet handling should use the same AGV fleet as loaded pallets or a separate workflow.