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Evolution of Pallet Scanning from Manual Methods to Industry Necessity

Pallet scanning, a once straightforward task in warehousing and logistics, has evolved significantly over the decades. What was once a manual, often tedious, process of tracking and managing pallets has now become a highly sophisticated workflow, driven by advances in pallet scanning technology and the rising complexity of supply chain demands.

The Early Days: Manual Pallet Tracking

In the early days of warehousing, the scanning and tracking of pallets relied heavily on manual processes. Workers would physically inspect pallets and record data by hand or using simple spreadsheets and ledgers. Labels, if they existed, were often handwritten, and verifying pallet contents required opening them up or visually confirming their products. This method was not only labor-intensive but also error-prone. Human errors in recording information, misreading labels, or misplacing documents often resulted in inventory discrepancies that disrupted supply chain operations.

The Introduction of Barcodes and Scanning Technology

The introduction of warehouse barcode reading in the late 20th century marked a turning point in pallet tracking and scanning. Barcodes, which allowed a unique identifier to be printed on each pallet or product, significantly reduced the time and effort needed to manage inventory. Paired with barcode scanners, this innovation enabled workers to quickly scan and track pallets as they moved through warehouses.

However, even as barcode technology became widespread, it was not without its limitations. Barcodes required a direct line of sight to be scanned, and manual scanning was still necessary. Workers needed to be close to the pallets to scan them, which introduced bottlenecks in large warehouses with high storage racks or when pallets were stacked deep. Additionally, barcodes did not provide a complete picture of the pallet.  Barcode scanners could not scan 2D codes, read alphanumeric text, detect damages, count boxes and visually record the pallet as it was being presented. It is very common for warehouses to experience misfires with their barcode scanners, contributing to incomplete data capture and process slowdowns.

The Promise of RFID in the Warehouse

As supply chain demands continued to increase in the early 2000s, industries began exploring more advanced methods of pallet scanning and tracking. Radio Frequency Identification (RFID) technology emerged as a promising solution, addressing many of the limitations associated with barcodes. Unlike barcodes, RFID tags could be read remotely without a direct line of sight, promising a faster, more efficient pallet scanning, even in hard-to-reach areas. But the industry quickly discovered the technology’s limitations, including:

  • High costs of implementation
  • Signal interference caused by liquids and metal
  • Complexity of system integrations
  • Accuracy challenges and privacy issues

And many more

Industry Trends Shaping the Importance of Pallet Scanning

The rapid growth of eCommerce, globalization of supply chains, and rising customer expectations have made pallet scanning a critical workflow in modern warehouses. Today’s consumers demand faster delivery times, real-time order tracking, and seamless experiences. As a result, companies must ensure their inventory management systems are as accurate and efficient as possible. Pallet scanning is at the heart of this need for precision.

Several industry trends have amplified the importance of pallet scanning:

  • Omnichannel Fulfillment
  • Global Supply Chains
  • Labor Shortages
  • Regulatory Compliance

The evolution of pallet scanning reflects the broader trends shaping the logistics and supply chain industry. What started as a manual process has evolved into a sophisticated, technology-driven workflow that is essential for managing the complexities of modern warehousing. Examples of this includes the robust line of pallet scanners from Vimaan, including:

The evolution of pallet scanning reflects the broader trends shaping the logistics and supply chain industry. What started as a manual process has evolved into a sophisticated, technology-driven workflow that is essential for managing the complexities of modern warehousing. As supply chains continue to grow in complexity and customer demands rise, pallet scanning will remain a critical part of efficient and accurate warehouse operations.

Pallet Scanning Automation Guide

As warehouse operations scale, the complexities surrounding pallet tracking and management increase significantly. Whether it’s verifying product SKUs, ensuring shipment accuracy, or optimizing warehouse space, pallet scanning plays a pivotal role in maintaining order and reducing costly errors.

Additional Pallet Scan Automation Resources

Pallet Scan Automation – Definitive GuideLabor trends in warehouses and how they impact pallet processing
Using RFID and Barcode Readers for Pallet Scanning versus Computer VisionWarehouse Pallet Scanning Challenges
How Automated 4-Side Pallet Scanning is Boosting Warehouse ProductivityTier-Height Pallet Counting Automation – VIMAAN
Drive Through Pallet Dimensioning is Finally an Option for Warehouses3 Ways to Maximize Pallet Processing Speeds and Quality

Automated pallet scanning demos

The Most Powerful Family of Pallet Scanners in the Warehouse

See firsthand how this diverse set of pallet scanning systems solve the most common and time intensive warehouse challenges including:

  • Fast barcode scanning and text reading
  • Ti-Hi Counting and SKU Verification
  • Non-stop drive through pallet dimensioning
  • Reconcile items that do not belong
  • Inspect for damages and more!
  • Get a custom pallet scanning system demo and discover how Vimaan can help improve pallet processing quality and speed, while reducing your operating costs,

 

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