Costco Pallet Requirements: A Painless Way To Ship

Knowing the fine details of Costco pallet requirements is essential if you want to become one of their vendors. Like many retailers around the country, Costco has a specific set of guidelines that palletized freight shipments have to follow. Fortunately, pallet requirements for palletized Costco freight can be easily broken down into some simple steps. 

Key Takeaways:

• Costco requires that pallets be no larger than 48”x40” and abide by ISBM-15.
• Packages must pass ISTA 1a and 3e testing requirements. 
• The lower layers of a pallet should be able to sustain 1500 to 2500 pounds based on the shipment's total weight.
• All palletized freight must be accompanied by a BoL, freight bill, and packing list.
• HAZMAT paperwork must accompany the pallet if HAZMAT goods are being shipped.

We’ll explain the specifics of Costco’s pallet requirements so you can successfully ship your palletized goods to them. 

How Should Costco Boxes Be Packed?

Before you can send a palletized shipment to Costco, you’ll need to make sure the individual boxes you’re using meet their expectations.

This includes:

• Boxes that survive long haul transit of 500 miles or more
• Packaging should be able to survive forklift, pallet jack, and mechanical layer clamping
• Packaging should be able to maintain integrity when in 80 - 90% humidity environments
• Packaging should be able to survive a minimum of four weeks in storage under load weight
• Packaging for refrigerated/freezer goods should be able to survive the refrigerated temperatures in moist environments 

Package testing is mandatory by Costco. They want all boxes to pass one of two tests held by the International Safe Transit Association (ISTA). 

This includes:

• ISTA Test Procedure 1A
• ISTA Test Procedure 3E

Costco is improving their sustainability efforts. As a result, all paper packaging materials should be certified as recycled paperboard content.

Acceptable certifications include:

• Forest Stewardship Council (FSC)
• Sustainable Forestry Initiative (SFI)
• Program for the Endorsement of Forest Certification (PEFC)

Requirements for plastic packaging materials include:

• Recyclable
• Compostable
• Biodegradable

Another goal of Costco is to reduce the amount of packaging, handling, and corrugated waste they have to handle. To achieve this goal, they require all packaging to be display-ready. 

What Are Costco’s General Guidelines for Pallets?

There are numerous expectations that you’ll need to meet when sending a pallet to Costco. In the next two sections, we’re going to discuss their requirements for pallet footprint, durability, and brand.

Pallet Footprint and Durability Requirements

When picking out a pallet or pallets to use for your shipment of freight to Costco, you’ll need to make sure that it has some of the following characteristics:

• Pallets should be no larger than 48”X40”
• General use block pallets only
• Pallets should be able to survive for over 500 miles while in transit

While pallets have a size limit of 48”X40”, Costco recommends using platforms with a 47.5” x 39.5” footprint. 

Acceptable Pallet Brand

Costco allows shippers to use a variety of pallet brands for their loads. We’ve provided a list of each one. 

• iGPS Pallets
• Peco Pallets
• CHEP Pallets

IGPS pallets are made of plastic, but Peco and CHEPS are made from wood. Plastic is a durable option, but if it breaks, you won’t be able to repair like you can with a wooden platform.

There are some occasions where using pallets made by the listed companies won’t be an option for you. For instance, you’ll likely need to use pallets made by other manufacturers if you’re sending your freight to a Costco location in another country. 

In such cases, you’ll still need to ensure they meet certain requirements, which I’ll review in the next section.

Heat Treatment and Fumigation Requirements

Pallets sent to Costco should abide by the heat treatment and fumigation requirements enforced by ISPM-15. Fortunately, there are many pallet manufactures that heat treat and fumigate their pallets prior to sale. 

Therefore, you won’t have to subject your platforms to either of these processes. Before buying pallets from a manufacturer, you can ask them if they abide by ISPM-15. You can also check the pallet prior to purchase for an ISPM-15 stamp that proves it’s been heat treated or fumigated. 

How Should Pallets To Costco Be Loaded?

Now that you know what platform to use, it’s time you learn how your cargo should be loaded onto your platform. We’ve broken down these complex processes into four basic parts. 

Stacking Procedures

Freight can be stacked on a pallet using a variety of different methods. Costco doesn’t specify which stacking method you should use in particular, but there are a few good rules to follow:

• Put the heaviest packages at the bottom of the pallet
• Use an overlapping stacking pattern
• Use a columnar stacking pattern for boxes that are the same and that are light

Having heavier packages on the bottom will prevent you from crushing light boxes. Costco also has requirements for stacking display-ready boxes.

The display section of these boxes should be facing outward on the 48” sides of the pallet. Lastly, there should be no overhang or underhang on your pallets. 

Freight that hangs over a pallet can become damaged by a forklift, and pallets with severe underhang will lose their structural integrity. If you want to give your palletized load extra protection, you can use rigid corner posts. Make sure the posts aren’t made of plastic and don’t bend when wrapped with stretch wrap. 

Load Dimensions and Weight

All palletized shipments sent to Costco should adhere to their strict load dimension and weight requirements. I’ve provided a table showing the accepted measurements your load will have to meet.

Costco also requires the bottom layer of your palletized load to withstand different amounts of weight. If your entire shipment weighs less than 750 pounds, the bottom layer should be able to withstand 1,500 pounds of weight. For shipments over 750 pounds, the bottom layer should be able to hold 2,500 pounds. 

Layer Sheets

Costco requires layer sheets for some, but not all, palletized freight shipments they receive to provide additional stability. 

The palletized shipments that do require layer sheets include: 

• Products in display-ready, corrugated packaging
• Bagged products over 10 pounds in weight

First, we’ll discuss Costco’s layer sheet guidelines for palletized shipments of display-ready corrugated packaging. For these loads, apply layer sheets in the following manner:

• Place layer sheets between product layers for items shipped or master displays that are already open (display modules that weigh more than 35 pounds should utilize a layer that is a minimum of 150 pounds of mullet test board)
• Use non-skid coated layer sheets for shrink-wrapped products or for products shipped in boxed packages that have surfaces that are smooth or slippery

If the top of your load is exposed, you can use a layer sheet to protect it from damage. Costco will also allow you to use a pallet cap. 

The layer sheet requirements for palletized bagged products are a little more simple. Simply place a sheet on the bottom layer of the product and on the top of the loaded shipment. 

Securing the Freight

Now that your freight is stacked, you’ll need to secure the freight that you’ve loaded onto your platform. As with the layer sheet requirements, Costco’s load securing requirements vary based on the freight that’s being transported. 

The following rules apply to products in display-ready corrugated packaging and products in fully enclosed corrugated shipping containers. 

Here are the steps:

1. Apply stretch wrap starting from the bottom of your pallet load and work your way to the top of the shipment
2. Wrap the shipment with a stretch film three times
3. Stretch film should be a minimum of .79 gauge

You can apply plastic strapping to give your palletized load more stability. However, metal strapping isn’t permitted. When it comes to bagged cargo, Costco will allow you to use one of three securing options: 

1. Use 1.2 millimeter one-side cling, puncture-resistant blown film. Wrap the palletized shipment a minimum of three times around the bottom third of the pallet load. Wrap the palletized shipment a minimum of three times on the top third of the pallet load. Afterward, wrap the pallet with stretch wrap from top to bottom.
2. Enclose your palletized load on all sides with a corrugated shroud. Stretch wrap the entire load to the bottom of the pallet. Make sure to use a minimum .79 gauge stretch film and wrap it around the pallet three times. Tie off the bottom end of the stretch wrap to the pallet. 
3. Put a corrugated 40”X48” tray around the palletized load. Make sure that the tray has a minimum height of 12” and stretch wrap the load to the bottom of the palletized shipment. A minimum of .79 stretch film is required and must be wrapped around the shipment three times. Tie off the end of the stretch wrap to the pallet.

What Documents Should Accompany Costco Pallet Shipments?

Costco doesn’t explicitly state which documents should accompany a palletized load, but it’s safe to say that you should include all the essential shipping documents with your load. 

The essential documents that you’ll need include the following:

• Bill of Lading (BoL)
• Freight Bill
• Packing List

If your palletized shipment has hazardous materials within its contents, you’ll need to include the appropriate hazardous materials paperwork. Our article on documents required for domestic shipping will provide you with more information. 

After Following Costco Pallet Requirements, Ship With USA Truckload

USA Truckload can find a carrier to transport your pallets to a Costco warehouse. We have a nationwide network of shipping providers that can pick up your cargo from anywhere in the country. When you choose USA Truckload, you’ll also gain access to a variety of other logistics services.

• Standard Truckload Shipping: We use state-of-the-art technology to ensure your carrier delivers your good on time. 
• White Glove Delivery: We have carriers that can deliver and install high value items like furniture, appliances, and electronics.
• Freight and Logistics Consulting: Get expert advice from Truckload expert during a 1-on-1 consulting session.

If you’re ready to ship, then fill out your Request for Proposal (RFP). Our team is also available at (866) 353-7178 if you have any questions about our services.