Palletization
Also known as: Pallet Loading, Pallet Stacking, Unitizing
Definition
Palletization is the practice of consolidating multiple boxes or items onto a pallet, securing them as a single unit for shipping. Proper palletization is essential for LTL and FTL freight—it protects goods, enables forklift handling, and optimizes trailer space.
Standard Pallet Sizes
| Type | Dimensions | Common Use |
|---|---|---|
| GMA (Grocery) | 48" × 40" | Most common in North America |
| EUR (Euro) | 47.24" × 31.5" | European standard |
| Half Pallet | 48" × 20" | Small loads, retail displays |
| Quarter Pallet | 24" × 20" | Small quantities |
The 48" × 40" GMA pallet is the North American standard.
Pallet Types
Wood Pallets
- Most common (90%+ of market)
- Inexpensive ($5-20)
- Recyclable/repairable
- Heavy (30-70 lbs)
Plastic Pallets
- Lightweight (10-25 lbs)
- Durable and reusable
- More expensive ($15-100+)
- Required for some industries
Presswood Pallets
- Made from compressed wood fiber
- Lighter than solid wood
- ISPM-15 exempt (international)
- Good for export
Palletization Best Practices
Building the Pallet
- Start with heaviest items - On bottom
- Create interlocking layers - Alternate box orientation
- Keep weight centered - Balanced load
- Stack to edges - Maximize stability
- Don’t overhang - Stay within pallet footprint
- Limit height - 48-60" typical maximum
Securing the Load
Stretch wrap:
- Wrap from bottom to top
- Overlap 50%
- Minimum 3 layers
- Secure to pallet base
Strapping:
- For heavy loads
- Through pallet openings
- Supplement to stretch wrap
Corner boards:
- Protect edges
- Add stacking strength
- Prevent strap damage
Pallet Weight Guidelines
| Freight Type | Weight Limit |
|---|---|
| Standard LTL | 2,500 lbs |
| Heavy LTL | 5,000 lbs |
| Floor loading | 10,000 lbs |
Verify with carrier—limits vary.
Common Palletization Mistakes
- Pyramid stacking - Creates weak structure
- Heavy items on top - Crushes lower boxes
- Overhanging boxes - Damage and instability
- Insufficient wrap - Load shifts in transit
- Mixing product types - Complicates receiving
- Exceeding height limits - Can’t stack in trailer
Calculating Pallet Quantity
Formula:
- Pallet area: 48" × 40" = 1,920 sq in
- Box footprint: L × W
- Boxes per layer: Pallet area ÷ Box footprint
- Total boxes: Boxes per layer × Number of layers
Example:
- Box: 12" × 10" = 120 sq in
- Boxes per layer: 1,920 ÷ 120 = 16 boxes
- 4 layers = 64 boxes per pallet
Palletization and Freight Class
Proper palletization affects freight class:
- Better density = lower class = lower cost
- Stackable freight classified differently
- Document dimensions accurately
- Include pallet weight in total
Ready to ship?
Compare shipping rates instantly
Try Free