How to Palletize Boxes for Truckload Shipping

Palletizing boxes is more difficult than you might think. Many shippers make mistakes, stacking or securing their load incorrectly, resulting in damage to their freight and dangers for others. To ensure your load stays in one piece, we’re going to give the essential guidelines you’ll need to palletize your freight.

Key takeaways:

• Between 30 and 60 boxes can be loaded on a pallet, but it all depends on the size of your boxes and pallet footprint. 
• Palletized loads can vary in height and weight based on the retailer. Acceptable  heights typically fall between 58” and 77”, with a weight between 1500 and 2500 pounds. 
• When palletizing freight, you’ll need to pick the right platform, pack and stack your boxes, secure your load, and apply the appropriate labels.
• You can use column, interlocking, pinwheel, or brick stacking when placing your boxes on a pallet. 

We’re going to discuss these details further and show you how to palletize your loads. 

Why Should You Palletize Boxes?

If you have a lot of boxes to ship, then palletizing them can be a good idea. First, palletizing your boxes keeps them all together, so you won’t have to worry about a box getting misplaced or lost. 

It also keeps the boxes secure and protected, so they are less likely to get damaged. Not only does palletizing your freight make it easier to keep track of your cargo, it also makes it much easier to move and store in large quantities. 

If you had 200 boxes that had to be moved, it would take a long time to load, unload, and handle one at a time. If your freight is on pallets, it can all be moved for a fraction of the effort in a fraction of the time.

Finally, a palletized shipment is easier to store, since they are compact and can be stacked on top of one another. Because of that, they save space in warehouses and trucks. 

Related: 8 Advantages of Palletization

How Many Boxes Fit on a Pallet?

You can load somewhere between 30 and 60 boxes on a pallet. However, the exact number of boxes that will fit on a pallet depends on various factors. 

These include:

• Size of boxes
• Pallet size
• Weight and height requirements

Shipping boxes and pallets can come in a multitude of sizes. We’ve provided a graphic that shows the common pallet and box sizes that are used for shipping freight.

Typically, 77” is the maximum height most businesses will allow for a palletized shipment. That said, the exact height can vary based on the retailer or grocery store you’re sending your freight to. For example, Walmart and Amazon have a pallet height maximum of 72”, while Costco’s is 58”. 

The weight that’s allowed on a pallet can differ as well. Some retailers will allow a maximum of 1500 pounds, while others will permit loads as heavy as 2500 pounds. How high and how much weight that can be placed on a pallet will influence how many boxes you’ll be able to load on it. 

You can learn more about Walmart and Amazon pallet requirements in our detailed guides.

5 Best Practices for Palletizing Boxes

Anyone can simply stack boxes on a pallet and call it a day, but there are a few best practices that you can utilize to add strength and stability to your palletized freight. 

Here’s a complete breakdown of the step-by-step process that will yield the best results:

1. Pick the Appropriate Pallet: Select a pallet that’s in usable condition. The platform can either be made from wood, plastic, or metal depending on where you’re shipping it. Make the footprint of the pallet is the correct size based on the retailers specifications. 
2. Choose and Prepare Boxes: Use boxes made from sturdy cardboard. After packing the boxes with the items you’ll be shipping, fill in any voids with packing material. Seal your packages with sturdy packing tape. 
3. Stack Your Boxes Evenly: Stack your boxes in a manner that distributes the weight evenly and utilizes the entire pallet. Make sure your heaviest boxes are on the bottom. Ensure your packages don’t hang over the platform. Use cardboard or slip sheets between each layer of boxes if you’re allowed. 
4. Securing the Load: Keep your freight in place on the pallet using stretch wrap. If permitted, you can also use straps to add extra security. 
5. Label: Place labels in the appropriate locations on your palletized load. 

Keep in mind, every retailer and grocery store you send your pallets to will have slightly different requirements. That said, the list of steps we’ve provided is a general baseline that you’ll likely come across.   If you're shipping pallets internationally, we have a guide that can help you with the process. 

What Stacking Methods Can I Use?

There are numerous stacking methods that you can use when placing packages on a platform, with each one having its unique pros and cons. The most important aspects of each are the even distribution of the weight and the stability of the load itself.

Stacking techniques include:

• Column
• Interlocking
• Pinwheel 
• Brick

We’ll briefly explain each one in the following sections. 

Column

Column stacking is when you simply place one box on top of the other. It’s a straightforward way of stacking that maximizes the compression strength of each box. 

However, it works best for boxes carrying lighter items. Column stacks are also more susceptible to falling over if they’re stacked too high. 

Interlocking

Interlock stacking arranges boxes in a staggered pattern on a pallet. This stacking method gives loads an increased amount of stability. Since boxes are overlapping, they support each other’s weight and distribute it more evenly. 

One downside of using the interlocking pattern is that it can make loading and unloading a pallet more time-consuming. 

Pinwheel

Pinwheel stacking alternates the orientation of boxes within each layer. As a result, the packages form a pinwheel pattern. This stacking method reduces gaps and is a great option for boxes of differing sizes.

That said, it’s not the best method to use if you’re shipping boxes with consistent dimensions. 

Brick

Brick stacking is when boxes are arranged in a staggered pattern that’s switched on every layer. This creates a brick-like pattern that allows the boxes to interlock. Using brick stacking prevents freight from shifting while in transit. 

It also distributes weight like the interlocking technique. The downside of brick stacking is that it reduces how many boxes you can fit on a pallet.  

Ship Your Pallets by the 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 they leverage to ensure you receive the best service possible. When you pick USA Truckload, 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.