Pallet building system

1. A material handling system for handling and placing packages onto pallets, the system comprising:

a storage array with storage space for holding packages therein;

an automated package transport system communicably connected to the storage array for storing packages in and retrieving packages from the storage spaces of the storage array;

an automated palletizer for placing packages onto a pallet to form a pallet load, the palletizer is communicably connected to the transport system which provides individual packages from the storage array to the palletizer for forming the pallet load; and

a controller operably connected to the palletizer and programmed with a pallet load generator configured so that the pallet load formed by the palletizer has more than one layer of stacked packages, wherein

at least one layer of which includes packages of different heights, the at least one layer having a substantially flat upper surface between a top surface of the pallet load and a base surface upon which the at least one layer is seated, and comprises more than one stacks extending from the base surface to the upper surface substantially independent of each other, at least one of the independent stacks being formed of packages having different heights.

2. The material handling system as in claim 1 , wherein more than one of the stacks is formed of packages having different heights.

3. The material handling system as in claim 1 , wherein the upper surface defines a seating surface for another layer of stacked packages.

4. The material handling system as in claim 3 , wherein the other layer forms another substantially flat upper surface between the top surface of the pallet load and the base surface.

5. A material handling system for handling and placing packages onto pallets, the system comprising:

a storage array with storage space for holding package therein;

an automated package transport system communicably connected to the storage array for storing packages in and retrieving the packages from the storage spaces of the storage array;

an automated palletizer for placing packages onto a pallet to from a pallet load, the palletizer is communicably connected to the transport system which provides individual packages from the storage array to the palletizer for forming the pallet load; and

a controller operably connected to the palletizer and programmed with a pallet load generator configured so that the pallet load formed by the palletizer has more than one layer of stacked packages, wherein

at least one layer of which includes packages of different heights, the at least one layer having a substantially flat upper surface between a top surface of the pallet load and a base surface upon which the at least one layer is seated, and comprises more than one stacks extending from the base surface to the upper surface substantially independent of each other, at least one of the independent stacks being formed of packages having different heights, and

wherein the upper surface defines a seating surface for another layer of stacked packages and at least one stack of the other layer bridges across different stacks of the at least one layer.

6. The material handling system as in claim 1 , wherein the pallet load generator has predetermined rules for arranging the different height packages in the more than one stacks.

7. The material handling system as in claim 5 , wherein the pallet load generator ha predetermined rules for arranging the different height packages in the more than one stacks.

8. The material handling system as in claim 5 , wherein more than one of the stacks is formed of packages having different heights.

9. The material handling system as in claim 5 , wherein the other layer forms another substantially flat upper surface between the top surface of the pallet load and the base surface.

10. An automated palletizer comprising:

an automated package pick device capable of moving packages from a package deposit section to a pallet to form a pallet load from packages;

a controller that is operably connected to the automated pick device, the controller having a pallet load generator configured to determine a pallet load structure of mixed packages;

the pallet load generator being programmed so that it determines the load structure from mixed package layers overlaid over each other, at least one of the mixed package layers being formed of stacks of mixed packages, top and bottom surfaces of the stacks corresponding to the at least one mixed package layer respectively forming top and bottom surfaces of the at least one mixed package layer that are substantially flat, wherein the top flat surface is a substantially uniform level seating surface for another of the overlaid layers, the seating surface extending over more than one of the stacks of mixed packages of the at least one mixed package layer; wherein

at least one of the more than one stacks of mixed packages has a composite package formed of more than one of the mixed packages arrayed alongside each other in a package array at a common stack level; and wherein

the controller generates commands for the pick device to build the pallet load from the load structure determined by the pallet load generator.

11. The automated palletizer as in claim 10 , wherein the stacks corresponding to the at least one mixed package layer are freestanding substantially independent of each other.

12. The automated palletizer as in claim 10 , wherein adjacent layers interlock the stacks corresponding to the at least one mixed package layer.

13. The automated palletizer as in claim 10 , wherein each of the mixed package layers is formed by stacks of substantially equal heights, the stacks being formed of packages of different heights, and being freestanding substantially independent of each other, and wherein the mixed package layers as well as layers formed by packages of the same height can be permuted on top of one another in a common pallet, or exchanged between different pallets of a common store order.

14. The automated palletizer as in claim 10 , wherein the mixed packages include an unstable package disposed in the package array forming the composite package.