Automated Storage and Retrieval Systems (ASRS) are transforming supply chains worldwide, allowing businesses to maximise storage density, reduce labor costs, and improve inventory accuracy ¹.
But for ASRS to run smoothly, every element of the system needs to work in harmony, from conveyors and shuttles to the pallets themselves. This means the efficiency of an ASRS is only as strong as the pallets it relies on. Pallets that aren’t designed for automation can jam conveyors, misalign in racks, or damage costly equipment.
That’s why choosing the right pallet is just as important as choosing the right software or racking design.
But first, what makes a pallet ASRS-ready?
Not all pallets can handle the speed and accuracy of automation. To be suitable for ASRS, a pallet must meet several critical requirements:
- Dimensional accuracy
Pallets in automated systems must conform to precise tolerances, often within a few millimeters, to avoid errors during robotic handling. - High load-bearing capacity
An ASRS pallet must support heavy loads dynamically without flexing, combining structural integrity with lightweight design for smooth machine handling. - Durability under constant use
Automated systems often run 24/7. Pallets need to withstand repeated handling without cracking, warping, or splintering. Plastic pallets, unlike wood, resist moisture and impact damage, extending their service life several times over ² . - Standardisation for global supply chains
ASRS-compatible pallets are designed to meet international standards such as ISO and JIS, enabling global scalability.
If you fulfill all the considerations above, you can avoid costly surprises when scaling automation, no matter what industry you operate in.
To make things easier for you, IntracoPallet offers expert support at every stage (from sampling and load testing to lifecycle planning) to ensure you find the pallet best suited to your needs.
Spotlight on IntracoPallet’s ASRS solutions:
A-Series: Designed for automation
The A-Series plastic pallets are the flagship choice for automated warehouses [LINK: A-Series page]. They deliver four key advantages that make them ideal for ASRS:
- Precision-engineered: Consistent dimensions reduce downtime and prevent system misalignments.
- Lightweight yet strong: Balances operator safety with high dynamic load capacity.
- Durable: Designed for repeated handling in high-frequency operations.
- Hygienic: Non-porous surfaces resist bacteria and make them ideal for industries like food, beverage, and pharmaceuticals.
- Steel reinforced : Endures heavy loads while maintaining minimal deflection on the rack.
- ASRS-compliant design: Flat-bottomed for smoother movement on conveyors with smooth surfaces for better sensor detection.
By combining these features, the A-Series ensures warehouses achieve maximum uptime and efficiency in their automated operations.
A side note about wood pallets and why plastic is the better choice
Plastic pallets offer several advantages over wood when it comes to automation:
- Consistency: Plastic pallets maintain precise dimensions; wood warps and splinters.
- Hygiene: Non-porous plastic surfaces are easy to clean, unlike wood which absorbs moisture and harbors bacteria.
- Longevity: Studies show plastic pallets can last several times longer than wood in continuous operations.
- Sustainability: Recyclable plastic reduces waste and supports circular economy goals.
- Stable and resilient: Plastic pallets maintain structural integrity even under heavy loads, outperforming wood alternatives that are prone to chipping/splintering and damaging systems
For businesses upgrading to ASRS, these benefits translate into lower downtime, improved safety, and long-term cost savings. IntracoPallet also supports customers through its buyback and recycling program [LINK: Sustainability page], ensuring damaged pallets are returned, recycled, and repurposed responsibly.
And don’t forget about your sustainability goals, either!
Today, corporate sustainability is no longer optional, it’s a must-do!
Plastic pallets play a critical role in reducing waste and supporting ESG commitments. IntracoPallet leads in this area through its 3R approach: Reduce, Reuse, Recycle [LINK: Sustainability page].
- Reduce reliance on wood and single-use pallets.
- Reuse pallets over a longer lifecycle with minimal maintenance.
- Recycle end-of-life pallets into new, high-performance products.
By going with IntracoPallet’s sustainable solutions, your business can strengthen both your supply chain and your corporate responsibility profile.
Make your warehouse future-ready with IntracoPallet
Today, ASRS adoption is accelerating at a rapid pace, with the global market expected to grow from about USD 10.65 billion in 2025 to over USD 21 billion by 2034 ³.
This means that the importance of using ASRS-ready plastic pallets cannot be overstated: Using pallets designed with precision, durability, and sustainability in mind help businesses unlock the full potential of automation, and failing to keep up only allows the competition to get ahead.Every ASRS is only as strong as the pallets it runs on. Get in touch and let us help you choose the right fit for long-term success.
