A new exact algorithm using the stair structure for the pallet loading problem

The pallet loading problem(PLP) requires the best orthogonal layout that loads the maximum number of identical boxes(small rectangle) onto a pallet(large rectangle). Since the high pallet utilization saves the distribution and storage costs, many heuristic and exact algorithms have been developed so far. Martins and Dell have found the optimal layouts for the all PLPs less than or equal to 100 boxes except for only 5 problems in their recent research. This paper defines the ‘stair structure’ and proposes a new exact algorithm applying it. In order to show the priority of the proposed algorithm, computational results are compared to previous algorithms and the optimal layouts for the 5 unsolved problems are given.