Palletizing

Palletizing

Link to Bill Wilmot's drawings showing packing 20 Pentium sets onto a pallet.

You seem quite eager to be indoctrinated into the secret palletizing ceremony. Here are some initial thoughts.

If you are beginning with a computer donation event, please see our pages on this. Please remember to test the equipment to be sure that it boots up and to inventory the equipment as you place it on the pallet. We would like to have the inventory in two places – visible through the shrinkwrap toward the top of the pallet and e-mailed to Pam or me.

For the customs documents, you need to let us know an accurate count of only the following (we need to know per container and per each pallet):

• Computers noting if Pentium II or III or IV with a count by level and how many have CD ROMs or modems
• Total number of boxes of keyboards and mice with count written on the outside of each box
• Total number of boxes of parts, software, peripherals, network pieces, speakers, etc with a word or 2 on the box
• Post 1996 Color Monitors with their video cables
• Total number of boxes of power cords with count written on the outside of each box
• Total number of printers with their data cables
• Total number of faxes, scanners, or network hubs, routers, or switches

* Before you start to put things onto the pallet make sure that the pallet is facing the direction that the pallet jack or fork lift can insert its prongs to be able to lift it once it is full.

Most of the computers above have been put on the pallet horizontally – I would suggest that you put all of them vertically with a layer of cardboard between each layer. You should be able to get about 16 computers per level.

WARNING: If you are going to use a pallet jack and a truck with a lift gate to move the pallet after it is full from your location to a shipping warehouse – you need to pay attention to not loading it as full as we discuss elsewhere here. A forklift can lift a pallet that is over 6 feet tall but a lift gate might NOT be able to do this – especially if you fill a pallet with all computers. A pallet jack on a steep driveway is also going to have a problem with a pallet that is too heavy. If you are using a lift gate – you might want to limit your height to one level of vertical computers (about 18) with two layers of 9 monitors each with some boxes on top. Possibly when the pallets are at the warehouse, they will allow you to place 1 third layer of 9 monitors on top of the other monitors and then put the boxes back on top. Also, if you are using a pallet jack and you have a steep drive way – you may want to use the pallet jack to move the pallets to a level area where you can position the truck with the lift gate instead of trying to have the truck get up a steep drive way.

You can only get 6 large or 9 regular monitors per layer. It is safer to have the monitors screen face down. Between each layer – cardboard works well. Between the sides of monitors you will need soft stuff in between so they don't smash into each other. Please do not use shredded paper or Styrofoam peanuts – as they will blow all around outdoors upon opening.

You can see the cardboard layer between the layers of monitors of the back pallet – it would be good if you could go a bit thicker (to just under ½ inch).

You could go up 2 levels of computers with 2 layers of unwrapped monitors & printers or boxes of mice, keyboards, or power cords on top. To hold enough - these pallets would be best going up to 6+ feet - but no more than 6"11". You need to make sure the trucker picking them up and the warehouse where they are going before being loaded into the container agree).

Free pallets are available at many stores, schools, and companies. Nurseries and tire stores are good bets. Just make sure that the way you arrange I on the floor – the fork lift or pallet jack will be able to access the slots it needs to enter to be able to lift the full pallet when you go to move it!

Two new rolls of stretch wrap should be enough for 10 pallets - 3-4 layers tightly around the whole pallet and across the top - remember to put an inventory page or number visible through the wrap so the warehouse and our partners know what to place in a future container - without having to undo what you are about to do. As you do each level you can put a tight wrap around that level to hold them.

When palletizing make sure you lean into pulling the stretch wrap - especially as you round the corners. You should have about 4 times around the whole thing by the time you are done. I like to make big Xs as well as going around. Every moving company and warehouse does this all the time – so you can watch or ask them advice.

Be careful to stay basically within the footprint of the pallet and to not have any of the monitor’s glass faces facing out so that they will come in contact with the fork lift or with the sides of the ocean shipping container.

As much as is feasible, please try and include on the pallets all of the needed power cords, keyboards, and mice in separate boxes along with one printer per ten computers.

In addition to the cardboard between each layer, it is very helpful if you can put a sturdy piece of cardboard around the side of the pallet for extra support and protection. This should be inside of your last layer of stretch wrap. This is to act like an external skeleton for what you have packed onto the pallet.

Once you start packing the pallet you will not be able to move it very far! If you do it in your garage on a Saturday or Sunday - they can come in and get the pallet on Monday or Tuesday and easily and quickly (on paved surface only) pull it on the pallet jack out to the truck that they will back up as close as they can and lower the hydraulic elevator type liftgate. If you are going to need to depend on a liftgate, please do not go over 5 feet high – this is because of the weight. With these shorter pallets, we will need to manually load additional items on top after they are placed in the ocean shipping container.

Once the equipment is on the pallet, it is a matter of Pam or me calling a freight company to see if they will bring the pallet to a warehouse we use. If you are not able to do all of this at a warehouse or place with a loading dock, we will need to make arrangements for the truck that comes to pick up your pallets to have a liftgate on the back and to bring their own pallet jack so that they can move the pallets.

We should coordinate with us the time you palletize so that we have a commitment for a pick-up so you do not have a pallet sitting in your garage or at the location that has donated space for too long.

Thanks for doing this.
timothy

The various offices of WCE have used everything from a 1,000 square foot testing, wrapping, storing space at which they do not accept donations for security reasons to a 150 sq. ft. storage place outside of which they test, inventory, and palletize (see attachment) and then the equipment goes to a warehouse until it is loaded into a container. One location actually accepts donations right at the site because the security is there. The palletizing route seems to make sense but it would be good to have a space that is large enough to sort and test computers as they come in and get them onto pallets as soon as possible - so that there is a limit on the number of times you have to touch each computer. Maybe 500 square feet as a minimum - with several electric outlets?

One other option is for you to think about co-locating with a computer-recycling center if it is near public transportation so that volunteers can get there.

Here in Hull, we use my basement and garage. My double garage can hold 8 full pallets. When we have 6 ready, a neighbor drives his forklift over and loads them onto his flat bed truck. It takes about an hour from the time he leaves his home until he is securely loaded. It used to take about half the time in a closed uhaul truck.

With the uhaul truck, we take the pallets to the warehouse and the warehouse forklift pulls out the first one and then they use a pallet jack that they pick up and put in the truck to pull the other pallets to the back so that the fork lift can reach them. Again this takes under half an hour from pre-arranged arrival until departure.

Drop-off can be at same place/time as volunteers are testing and palletizing computers. It would be great if this has forklift and/or loading dock. If not, you can rent a truck with a lift gate on the back and then you need to rent or borrow a pallet jack.

Then as soon as 3 or 4 pallets are ready, inventoried, and have a clear label with an identifying number and a summary of contents - then they should be taken to a commercial shipping warehouse where they can be stored until we are ready for a shipment that needs those pallets.

This plan allows for you to use a smaller space. Some places allow for you to test and palletize outdoors for a day and have a truck come at the end of the day or first thing in the morning to take the pallets to the warehouse. Some places also allow for individuals to bring donations at times when they are open and your volunteers are present. For example, WCE San Francisco does 10-Noon on the first Saturday morning of each month.

Josh Goodwin and Colin Maclay in Hull, Massachusetts awaiting the arrival of the rental truck. Please note Colin's "safe" footware! The sign of a true professional - please do not try this when you are packing!