How to Palletize A Shipment

Quick Answer

To successfully palletize a shipment for freight shipping:

1. Pack Your Boxes Carefully: Use sturdy boxes, provide cushioning, fill empty spaces, seal securely, and label each box.
2. Pick the Appropriate Pallet: Choose a wooden, plastic, or metal pallet in the correct size, typically 48” x 40”, unless otherwise specified.
3. Stack Your Freight: Follow weight and height guidelines, use a stable stacking method, place heavy items at the bottom, avoid overhang, and fill gaps.
4. Use Slip Sheets: Place slip sheets between layers (if allowed) to improve load stability and facilitate unloading.
5. Inspect Your Load: Check for loose items, pallet damage, and uneven weight distribution before securing.
6. Secure Your Freight: Wrap tightly with stretch wrap from base to top, or use strapping for extra stability if permitted.
7. Label Cargo: Apply pallet labels with shipping details, barcodes, and handling instructions on at least two sides.

Palletizing shipments is more difficult than you might think. Many shippers make mistakes by stacking or securing their load incorrectly, which results in damage to their freight and endangers cargo belonging to other shippers. 

To ensure your load stays in one piece, we’re going to give you the essential guidelines you’ll need to palletize your freight.

How To Palletize Your Freight One Step At A Time

Before we get started, it should be noted that palletizing requirements will vary based on the business or retailer that will receive your shipment. The steps we’re going to discuss are the general rules you should follow. That said, you should always check any specific rules your receiver might have in place to ensure your palletized load is compliant. 

1. Pack Your Boxes Carefully

Even though your freight is going to be stacked and secured to a pallet, you’ll need to ensure your individual boxes are packed correctly. This guarantees extra protection for your freight as it travels through the supply chain. 

To ensure your boxes are packed correctly, follow these practices:

• Select sturdy boxes
• Provide adequate cushioning
• Fill empty spaces
• Seal boxes securely
• Place box labels

Make sure the boxes you decide to use are in good condition and are made from sturdy cardboard. Reusing boxes is acceptable, but only if they are free from holes, rips, or dents.

Wrap your items individually using materials like bubble wrap, foam inserts, or packing peanuts to protect them from shocks and vibrations. You can use similar packing materials to fill in any voids to prevent your goods from shifting inside the box while in transit. 

You don’t want your packages to come open while in transit. Use durable shipping tape that will keep them closed. While you’ll eventually put a pallet label on your load once it’s secured, your individual boxes should also have labels once they’ve been packed. 

2. Pick the Appropriate Pallet

Next, you’ll need to use the appropriate pallet that will carry your load. First, you’ll need to choose your desired pallet material.

• Wooden Pallets: Widely used due to their durability and cost-effectiveness, wooden pallets are ideal for heavy loads. However, they can be susceptible to damage and are more challenging to clean.
  
• Plastic Pallets: Lightweight, durable, and resistant to moisture and chemicals, plastic pallets are preferred in industries such as food, pharmaceuticals, and chemicals. While they offer longevity and hygiene benefits, they come at a higher cost and may deform under excessive weight.
  
• Metal Pallets: Designed for heavy-duty applications, metal pallets provide superior strength and durability. They are ideal for transporting machinery and industrial equipment but tend to be heavier and more expensive than other options.

Just about every retailer allows wooden pallets. If you want to use plastic or metal platforms, you’ll likely need to gain approval first.

Next, you’ll need to use pallets that are the right dimensions. The most commonly used platform is the Grocery Manufacturers Association’s (GMA) 48” x 40” pallet. 

Most retailers will want you to use this specific type of pallet. However, some may allow you to use other platform sizes, such as 42” x 42” and 48” x 48” platforms.

Related: Shipping Skid vs Pallet

3. Stack Your Freight

Stacking your freight is one of the most important steps of palletizing a shipment. If you don’t stack your freight efficiently, it can weaken the stability of your load. First, you’ll need to determine the type of pallet load you’ll be shipping. 

The three types of pallet loads include:

• Type A: This is a palletized shipment that consists of freight with a uniform shape that matches the size of the pallet. These loads form a cube, have flush edges, and are easy to wrap.  
• Type B: Palletized shipments that fall under this category have different-sized cargo that doesn’t fit the size of the pallet. They don’t have flush edges, but still create the shape of a cube.
• Type C: These shipments also have cargo with different shapes and sizes, except they’re unevenly stacked. They may require more stretch wrap to be secured. 

Knowing what type of load you’ll be shipping will help you stack your freight more carefully. Best practices when stacking include:

1. Adhere to weight and height requirements
2. Use a reliable stacking method
3. Place heavy items at the bottom
4. Avoid overhang
5. Fill in any gaps

Before stacking your freight, check the height and weight requirements of the retailer or business that will receive your shipment. Each one will have slightly different rules you’ll have to follow. 

For example, Costco’s maximum pallet height is 58”, while Walmart and Amazon’s maximum pallet height is 72”. Similarly, Amazon’s maximum weight is 1,500 pounds, Costco’s is 2,500 pounds, and Walmart’s is 2,100 pounds. 

Next, you’ll need to pick a stacking method. Most retailers won’t care which one you use, as long as the load is secure. 

Stacking methods include:

• Column: Cargo is aligned directly on top of each other and forms vertical columns.
• Interlocking: This involves arranging packages in a staggered pattern, where each box overlaps the one below it.
• Pinwheel: The pattern arranges freight in a radial or spiral configuration, resembling the shape of a pinwheel.
• Brick: Mimics the pattern of a traditional brick wall, where each layer is staggered to overlap the gaps of the layer beneath.

It should be noted, the listed methods are the best for type A and type B loads. For type C loads, you’ll need to arrange your freight in a manner that ensures the stack is stable. This can vary based on the actual freight that will go on your platform. 

Regardless of which stacking method you choose, make sure the heaviest items are on the bottom of the pallet. Placing the heavier items at the bottom lowers the stack’s center of gravity. It also prevents damage to smaller and lighter items. 

Make sure none of your cargo hangs over the pallet. Overhanging freight weakens the stability of the pallet. Your freight could be damaged by the forks of a forklift as well. 

Finally, fill in any gaps on your stack. This can be difficult for type B and type C loads that don’t have a uniform shape. Nonetheless, try to fill in the voids by condensing your freight as close together as you can.  

4. Use Slip Sheets

Using slip sheets in between the rows of freight that’s stacked on your pallet will increase the stability of the load. If you have the approval of the receiver of your freight, you can even place one at the bottom of the stack.

This can make the unloading process much easier. A forklift equipped with a push/pull attachment can easily grab the bottom sheet and pull the load onto the forklift’s platens. 

While slip sheets are advantageous, retailers and businesses will have differing guidelines regarding their use. Some only allow you to use them between rows, while some companies forbid their use altogether. 

5. Inspect Your Load

Now that all your freight is stacked on the pallet, it’s time to give it a quick look over. Taking the time to check your load helps you identify any problems before you secure it. 

Things to look out for include:

• Loose or hanging freight
• Structural problems with the pallet
• Uneven weight distribution

If you identify any mistakes with your shipment, then take the time to correct it before proceeding. 

6. Secure Your Freight

After you’ve checked your load, you’ll need to secure your cargo to the pallet. The most common way of achieving this is with a clear stretch wrap. 

To apply your stretch wrap, follow these steps:

1. Begin wrapping from the base
2. Wrap upward in a spiral motion
3. Secure wrapping at the top of the load
4. Finalize wrapping    

Start by securely attaching the shrink wrap to a corner of the pallet, or tuck it under the pallet to anchor it. Circle the shrink wrap around the base of the pallet multiple times, overlapping each layer by approximately 50%. This ensures the load is securely attached to the pallet and prevents shifting.

As you move upward, keep consistent tension on the shrink wrap to ensure a tight and secure application. Each pass should continue to overlap the previous layer by about 50%, reinforcing the strength of the wrap and eliminating gaps.

Once you reach the top, extend the shrink wrap over the top surface of the load to provide additional stability and protection. After covering the top, continue wrapping downward in a spiral motion, maintaining tension and overlap, until you reach the base again.​

After wrapping your freight, cut the shrink wrap and press the end against the load to secure it. Ensure it adheres well to prevent unraveling. Check for any loose areas or gaps in the wrap, and if you find any, reinforce those sections with additional layers. If you have a wrapping machine, using it can automate the process. 

In some cases, retailers might allow you to use straps to provide greater load stability to your pallet. There are different materials that are used for straps, each one with varying levels of durability.

This includes:

• Steel strapping
• Polypropylene
• Polyester

To apply strapping, follow these steps:

1. Slide straps under pallet
2. Bring straps over the load
3. Secure strap with tension
4. Trim excess strapping

Slide the straps under the pallet's runners (the spaces between the pallet's bottom deck boards) to anchor them securely. Bring the straps up and over the load, ensuring they align with the edge protectors and are positioned to maximize stability.

For manual strapping, use a tensioner tool to tighten the straps firmly around the load. Once at the proper tension, apply seals using a sealing tool to lock the straps in place. After securing, trim any excess strapping material to prevent snagging or interference during handling and transportation. 

Related: 8 Advantages of Palletization

7. Label Cargo

Now that your pallet is stacked and secured, it’s time to apply your pallet labels. The requirements can vary, but you’ll most likely have to place labels on at least two sides of the load. However, some retailers will want labels on all four sides. Each label should also be in the center of each side they’re placed. 

Pallet labels should have the following information:

• Serial Shipping Container Code (SSCC)
• Product information
• Shipper and receiver details
• Handling information
• Logistic measures
• Barcode

The label on your load will ensure your pallet is handled with care and can be tracked accurately as it travels from one location to the next.  

Are There Alternatives To Shipping with Pallets?

Most businesses and retailers will want to receive your bulk shipments on a pallet. That said, some may allow you to ship non-palletized freight to their stores or warehouses. 

When using this shipping method, boxes won’t be attached to a pallet. Instead, it will be loaded into a trailer and stacked on top of other boxes. 

Shipping non-palletized freight can help you maximize the space you use in a trailer. It’ll also reduce the costs you’ll spend on using a platform to hold your cargo. However, it’s not the safest method to use when shipping fragile items. 

Ship Your Pallets by the Truckload with USA Truckload

Here at USA Truckload, we specialize in organizing and shipping palletized loads. We use a massive network of carriers to move freight for our customers. Our leadership also has decades of logistics experience which they leverage to ensure you receive the best service possible. When you pick USA Truckload Shipping, you’ll gain access to a variety of transportation options.

• Standard Truckload Shipping: We use state-of-the-art technology to secure reliable carriers that will ship your freight. 
• Expedited Shipping: With our 99.5% on-time rate, we guarantee your freight will arrive on time at the final destination.
• Freight and Logistics Consulting: Get expert advice from our truckload experts that will help you master the supply chain.

Start your partnership with USA Truckload by filling out your Request for Proposal (RFP). You can also contact us through the site or give us a call at (866) 353-7178.