Warehouse automation is moving beyond individual machines.
– In 2026, businesses are increasingly looking at how products move through the complete warehouse process — from receiving and storage to palletising, picking and loading.
– At MODEX 2026, robotic palletising and depalletising were highly visible across the exhibition floor, including systems capable of building mixed-product pallet loads. The trend reflects increasing attention on end-of-line automation and how products move from production into warehouse and distribution operations.
– Maersk also identifies automation as one of the major trends shaping warehousing in 2026, alongside AI, supply-chain resilience and changing operating requirements.
– But installing robots, conveyors or automated storage systems is only one part of automation. The products moving through those systems also need to be prepared for them. And that includes the transport packaging.
1 – Automation Changes What Packaging Needs to Do
– Traditional warehouse operations can often accommodate a certain amount of variation.
– An experienced forklift operator, for example, may compensate for:
– Slightly uneven pallet loads
– Different box positions
– Damaged corners
– Irregular pallet dimensions
– Loose wrapping
– Small amounts of load movement
– Automated equipment is different.
– Automation generally depends on predictable inputs.
– The more consistent the load, dimensions, position and handling points are, the easier it becomes to design a repeatable material-handling process. Transport packaging therefore becomes part of the automation conversation.
– The question is no longer only:
– “Will the packaging protect the product?”
It also becomes:
– “Will the packaged load move consistently through our logistics system?”
2 – Why Consistency Matters in Automated Warehouses
– Modern warehousing increasingly involves combinations of:
– Conveyors
– Automated Storage and Retrieval Systems
– Robotic palletisers
– Automated guided vehicles
– Autonomous mobile robots
– Automatic wrapping systems
– Automated loading systems
– Warehouse-management software
– Daifuku notes that mixed-case palletising and automated loading are receiving growing attention in 2026 as companies continue trying to automate areas that traditionally required manual handling.
– Packaging therefore needs to be considered together with the handling system.
– A shipment with inconsistent dimensions or unstable products may create more difficulties as handling becomes increasingly automated.
1. Start With a Stable Unit Load
– Automation begins with stability.
– A palletised load should remain correctly positioned while it is:
– Moved
– Accelerated
– Stopped
– Lifted
– Transferred
– Stored
– Wrapped
– Loaded
– A load that shifts during one of these operations may no longer have the same shape or dimensions expected by the handling system.
– That makes pallet-load design important.
– Eltete Malaysia provides Edgeboard as part of its protective transport-packaging range. The company identifies functions including edge protection, load stability, stacking support and strapping protection.
– When correctly designed for an application, Edgeboard can form part of the complete load-stabilisation system together with appropriate wrapping or strapping.
– However, Edgeboard should not be viewed as a solution for every unstable pallet. The complete load needs to be assessed.
2. Keep Packaging Dimensions Predictable
– Automated systems generally operate more effectively when they know what to expect.
– Packaging dimensions influence:
– Conveyor clearance
– Storage locations
– Pallet patterns
– Robot movements
– Load-centre calculations
– Wrapping
– Truck and container loading
– This makes packaging dimensional consistency increasingly important. A company with dozens of unnecessary box sizes or unpredictable pallet configurations may create additional complexity throughout its material-handling operation.
– This does not mean every product must use identical packaging. Instead, businesses can review whether their packaging portfolio can be simplified and standardised where practical.
– Eltete Malaysia states that its transport-packaging solutions can be developed according to product, handling method, destination, strength requirements, available space, material use and cost expectations. That approach is particularly relevant when packaging needs to interact with a defined warehouse process.
3. Avoid Unnecessary Pallet Overhang
– Pallet overhang occurs when cartons or products extend beyond the footprint of the load base.
– This can already create transport risks in conventional logistics.
– In automated environments, inconsistent overhang can create an additional dimensional variable.
– A correctly designed pallet configuration should therefore consider:
– Product dimensions
– Pallet dimensions
– Layer arrangement
– Weight distribution
– Handling direction
– Required protection
– Eltete’s existing packaging guidance recommends arranging products within the pallet footprint where possible and selecting the pallet according to the dimensions of the load.
– The objective is to produce a predictable transport unit rather than forcing every product onto an unsuitable standard base.
4. Protect Corners Without Creating Unnecessary Bulk
– Product corners remain vulnerable regardless of whether handling is manual or automated.
– Repeated transfers can expose cartons to:
– Pressure
– Impact
– Strapping tension
– Stacking loads
– Contact with surrounding cargo
– But adding packaging everywhere is not necessarily the best response.
– Targeted protection can be more efficient.
– Eltete Edgeboard is manufactured from laminated paperboard and can be positioned around vulnerable edges as part of a suitable packaging configuration.
– This allows packaging designers to reinforce specific areas instead of automatically increasing material around the entire shipment.
– For increasingly automated logistics operations, this principle can be valuable:
– Protect where protection is required while maintaining predictable external dimensions.
5. Review the Load Base
– The load base is one of the most important parts of any material-handling system.
– Companies may use:
– Conventional pallets
– Paper Pallets
– Pallet runners
– Slip Sheets
– Integrated box-and-runner structures
– Different systems require different equipment.
– Eltete Malaysia offers several paper-based pallet and load-handling solutions, including Paper Pallets, Slip Sheets, PallRun®, EdgeRunner® and BoxRunner.
– The correct choice depends on the complete logistics system.
– For example, Eltete’s Solid Slip Sheets are designed for suitable palletless-handling applications and are typically used with compatible handling equipment such as Push-Pull systems.
– A business should therefore never replace a pallet with a Slip Sheet simply because it uses less material. The receiving facility, handling equipment and complete supply chain must support the system.
6. Packaging and Handling Equipment Must Be Designed Together
– This becomes particularly important as warehouses automate.
– A packaging decision made only by procurement may create difficulties for warehouse operations. Likewise, automation equipment selected without considering packaging may require businesses to redesign their loads later.
– A better approach involves:
– Packaging
– Warehouse operations
– Engineering
– Logistics
– Procurement
– The teams should review the transport unit together.
– Questions could include:
Q – How will the load be picked up?
– Forklift?
– Push-Pull equipment?
– Conveyor?
– Automated vehicle?
Q – Where are the handling points?
– Can equipment consistently access them?
Q – Is the base suitable?
– Does it remain stable throughout the handling cycle?
Q – Are the dimensions consistent?
– Can the system reliably detect and move the unit?
Q – Is the load stable?
– Will cartons remain in their intended position?
Q – Can the packaging tolerate repeated handling?
– Consider the complete movement path, not only one operation.
7. The Pallet Is Becoming Part of the Automation System
– One interesting trend from MODEX 2026 was the increased attention not simply on robotics, but specifically on how pallets are built.
– Robotic systems were demonstrated stacking, unstacking and creating mixed-SKU pallet loads. This highlights a broader change.
A pallet should no longer be viewed only as:
– Something placed underneath the product.
– It is becoming part of a larger material-handling architecture.
– The pallet dimensions, openings, load arrangement and external stability can influence how efficiently products move through the warehouse.
– This creates an opportunity for manufacturers to review their load platforms before investing heavily in automation.
8. Box and Pallet Can Become One Packaging System
– Another interesting concept is integrating the handling base directly into the packaging.
– Eltete’s BoxRunner is one example.
– BoxRunner is a self-adhesive paper-board pallet runner that can be attached beneath a suitable carton box or display. The runner allows the box to function as a pallet-style handling unit instead of requiring a separate conventional pallet in appropriate applications.
– Eltete identifies options including two-way and four-way handling depending on the approved configuration.
– This does not automatically mean BoxRunner is suitable for every automated warehouse.
– The product weight, dimensions, runner placement, base strength and handling system still need to be evaluated.
– But the concept demonstrates an important direction in packaging design:
– Packaging and material handling can increasingly be engineered as one system.
9. Packaging Should Support Automation, Not Create More Complexity
– A warehouse can invest in advanced technology and still experience inefficiency if the loads entering the system are inconsistent.
– Consider two scenarios.
– Scenario A
– Every incoming pallet has:
– Different dimensions
– Irregular overhang
– Different stacking patterns
– Weak corners
– Loose stretch film
– Variable handling bases
– Scenario B
– Loads follow clearly defined specifications for:
– Dimensions
– Base
– Product orientation
– Weight distribution
– Protection
– Wrapping
– Handling direction
– Scenario B creates a more predictable environment.
– This does not mean every shipment will be identical.
– But reducing unnecessary variation can make warehouse processes easier to manage.
10 – Box and Pallet Can Become One Packaging System
– Another interesting direction is integrating the handling base directly into the packaging. Eltete’s BoxRunner is one example.
– BoxRunner is a paper-board pallet runner that can be attached underneath a suitable carton box or display. In suitable applications, the runner enables the box to function as a pallet-style handling unit instead of requiring a completely separate conventional pallet.
– Different configurations can provide different handling possibilities depending on the approved design. This does not automatically mean BoxRunner is suitable for every automated warehouse.
– Factors including:
– Product weight
– Dimensions
– Runner position
– Base strength
– Load distribution
– Handling equipment
– still need to be assessed.
– However, the concept demonstrates an important direction in modern transport-packaging design:
– Packaging and material handling can increasingly be engineered as one system.
11. Packaging Should Support Automation, Not Create More Complexity
– A warehouse can invest in advanced technology and still experience inefficiency if the loads entering the system are inconsistent.
– Consider two scenarios.
– Scenario A
– Every incoming pallet has:
– Different dimensions
– Irregular overhang
– Different stacking patterns
– Weak corners
– Loose stretch film
– Variable handling bases
– Warehouse equipment constantly needs to deal with variation.
– Scenario B
– Loads follow clearly defined specifications for:
– Dimensions
– Base
– Product orientation
– Weight distribution
– Protection
– Wrapping
– Handling direction
– Scenario B creates a more predictable environment. This does not mean every shipment will be identical. Manufacturers may have hundreds or thousands of different products. But reducing unnecessary variation can make warehouse processes easier to manage.
– Automation should simplify the material flow. Packaging should support that objective rather than introduce additional complexity.
12. Is Your Transport Packaging Ready for Automation ?
– Businesses planning warehouse automation should review more than robotics and software. The transport packaging itself should also be evaluated.
– Consider these questions:
Q – Is the unit load stable ?
A – Products should remain in the intended position throughout normal handling.
Q – Are the external dimensions predictable ?
A – Unnecessary variation can create additional complexity.
Q – Is pallet overhang controlled ?
A – Loads should remain within their intended footprint wherever practical.
Q – Are vulnerable edges protected ?
A – Protection should focus on areas exposed to pressure, impact and strapping.
Q – Is the load base suitable for the equipment ?
A – The pallet, Slip Sheet or runner system should match the actual handling process.
Q – Can the shipment tolerate repeated transfers ?
A – Automated warehouses may move loads through several handling stages.
Q – Have packaging and automation teams discussed the same transport unit ?
A – Warehouse equipment and packaging should not be developed independently when they need to work together.
– The objective is not to create a special type of “automation packaging.” The objective is to create a transport unit that is stable, predictable and appropriate for the way it will actually be handled.
Frequently Asked Questions
Q – What packaging is suitable for warehouse automation ?
A – There is no single packaging format that is suitable for every automated warehouse. The correct solution depends on the product, dimensions, weight, load distribution, warehouse equipment, transport conditions and destination. Stable loads and predictable external dimensions are particularly important considerations.
Q – Can Paper Pallets be used in automated warehouses ?
A – Paper Pallets can be considered for suitable applications, but compatibility should be evaluated against the specific handling system. Pallet dimensions, entry points, strength requirements, load distribution and warehouse equipment should all be assessed before implementation.
Q – Can Slip Sheets be used with warehouse automation ?
A – Slip Sheets can be suitable for certain material-handling systems, but they require compatible equipment. For example, Push-Pull equipment is commonly used for Slip Sheet handling. The complete supply chain, including the receiving location, should be considered before changing from pallets to Slip Sheets.
Q – Why is pallet load stability important for automation ?
A – Automated systems generally rely on predictable load position and dimensions. If products shift during transportation or handling, the shape and position of the unit load may change. A stable load helps maintain the intended transport-unit configuration throughout the logistics process.
Q – What role does Edgeboard have in automated logistics ?
A – Edgeboard can be used as part of a complete transport-packaging configuration to protect vulnerable edges, support load stability and protect cartons underneath strapping. Its suitability and specification should depend on the actual application and load requirements.
Q – Should packaging be reviewed before installing warehouse automation ?
A – Yes. Packaging influences dimensions, stability, handling points, pallet configuration and how the transport unit interacts with warehouse equipment. Reviewing transport packaging during the automation-planning stage can help businesses identify potential incompatibilities before equipment is fully implemented.
13 – Smarter Warehouses Need Smarter Transport Packaging
– Warehouse automation is changing how products move. Robots, conveyors, automated storage, AGVs and intelligent warehouse systems may increase the speed and consistency of material handling. But every automated process still needs something physical to move.
– That physical unit consists of the product and its packaging. If the transport unit is unstable, inconsistent or poorly matched to the handling system, advanced warehouse technology cannot automatically correct the packaging problem.
– This is why transport packaging should be considered as part of the wider logistics system. For manufacturers preparing for increasingly automated operations, the goal should not simply be to add more packaging.
– It should be to design the right packaging for the complete journey. Stable where stability is required. Protected where protection is required. Consistent where automation requires predictability. And designed around the way the product will actually be handled. Warehouse automation is getting smarter.
– Your transport packaging should be ready to move with it.
– Eltete Malaysia develops paper-based transport packaging solutions for industrial handling, storage and transportation.
Explore transport packaging solutions at:
www.eltete.com.my
