19 January 2026
When Pallet Paths and Carton Paths Must Split
Why mixing full-pallet and broken-case movement on the same aisle slows wholesale pick lines more than headcount shortages.
Wholesale operations often treat every aisle as dual-purpose. That works when volume is light. It breaks when full pallets and hand-picked cartons share the same metre of floor during the same hour.
Separate the heavy path from the light path as early as the first turn after receiving. Even a painted lane that reserves the centre for pallet jacks and the edge for hand carts reduces stop-and-go traffic. The gain is not theoretical — loaders finish routes with fewer reverse manoeuvres.
If your building cannot spare a dedicated aisle, time-slice the shared space. Morning pallet moves, afternoon carton picks, with a clear handoff window. The rule only works when it is posted at both ends of the aisle and enforced by the shift lead.
Movement maps make these choices easier to defend with owners who prefer a single “flexible” corridor. Flexibility without a rule becomes congestion by noon.