- Dynamic Pallet-building technology from Lucas Systems ties real-time picking data to smarter, safer pallet loads
- Veritable Vegetable sees improved route efficiency and order flexibility using Dynamic Pallet Builder
June 17, 2025 – Wexford, PA – Lucas Systems has announced the launch of its new Dynamic Pallet Builder software, a configurable and responsive tool designed to help warehouse workers build smarter, more efficient pallet loads in real time. The solution integrates with warehouse management systems (WMS) and supports dynamic decision-making based on a continuous stream of operational data.
According to Lucas Systems, the software makes thousands of calculations per minute, factoring in product dimensions, stacking rules, shipping constraints, worker travel, route sequence, and priority levels. As orders are received and updated throughout the day, pallet-building recommendations are recalculated dynamically.
“It’s constantly and dynamically optimizing throughout the day,” said Ken Ramoutar, Chief Marketing Officer at Lucas Systems. “Smarter pallet building also means smarter picking. Building better pallets can have a significant impact on reducing damage, minimizing worker travel, reducing transportation mileage and improving productivity.”
While many technologies focus on upstream order fulfillment or downstream transportation routing, Lucas Systems emphasizes the importance of tying pallet construction logic directly into picking workflows.
One company already seeing benefits is Veritable Vegetable, an organic produce distributor based in California. The company employs Dynamic Pallet Builder in a voice-directed picking process that splits pallets in alignment with delivery route requirements and truck configurations.
“This personalized approach provides optimal efficiencies for us, and it also gives our customers more flexibility when placing orders,” said Mary Jane Evans, Owner and CEO of Veritable Vegetable. “Both are extremely important.”
Palletizing Produce: A Complex Balancing Act
Fresh produce warehouses present unique palletizing challenges. A single outbound pallet may contain mixed SKUs packed in RPCs, corrugated trays, vented boxes, polybags, or bulk bins. These items vary widely in size, stackability, and crush resistance, requiring careful attention to weight distribution and airflow.
Beyond structural stability, moisture from wet or iced products can drip down and damage packaging or contaminate unpackaged items beneath. On top of that, traceability and label visibility requirements may restrict how packages are oriented. These constraints often make manual pallet building slow and error-prone, particularly when trying to match both warehouse and retailer-specific handling rules or when working around existing warehouse pallet rack systems.
Technologies like Lucas’s Dynamic Pallet Builder aim to reduce the margin for error while keeping pace with high-throughput environments and frequent last-minute changes to delivery plans.
Ramoutar noted that flexibility is key: “Warehouse agility is paramount for today’s complex logistics environments, and that’s why we’ve invested in a number of dynamic-driven technologies over the last year,” he concluded.
About Lucas Systems
Lucas Systems specializes in software solutions for distribution center performance, combining AI, machine learning, optimization models, and voice technologies to improve productivity and agility on the warehouse floor.
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Rick LeBlanc, EMBA, is the founder and editor of Reusable Packaging News (subscribe to the free newsletter) and editor of Western Pallet Magazine. A supply chain journalist with more than 30 years of experience, he specializes in pallets, reusable packaging, material handling and related operations. Rick is co-author of Pallets: A North American Perspective and Pallets & Progress: A Collected History of Pallets and Palletized Handling 1922–1945. He is also an advisory board member of the Virginia Tech Center for Packaging and Unit Load Design. Read Rick’s full bio.
