I helped lay out a sample pallet for a proposed FR10 station in our packing room. We used filled boxes and it looked reasonable until the tool designer brought a plywood outline of the fingers.
Giving the fingers room moves one carton off the supporting edge below. Closing that gap makes the tool withdrawal look doubtful. I'm the apprentice who'll get called when it stops, so I'd like to understand what we're signing up for. Has anyone organised a useful check of both things together?
Can you try one layer without alternating the orientation? Same filled boxes and finger outline. That should tell you cheaply whether the rotation is creating the conflict or whether every version needs a different tool.