How to Pack Your Pallet: 7 Techniques to Improve Pallet Density & Stability

how to pack your pallet
Facebook
Twitter
LinkedIn
Print
Email
7 Tips for Improving Pallet Density & Stability

It takes a lot of work by a lot of people to ensure that the millions of goods shipped each day arrive at their final destinations on time and in good condition. But for every 100 shipments that arrive unscathed, there are a few that arrive in less-than-perfect condition, and sometimes, the damages sustained during shipment can be attributed to nothing more than easily avoidable packing errors.

If your business has been bitten by packing mistakes in the past, take a look at our tips for building a better pallet.

Tip 1: Heavy goods go first

When deciding how to arrange your boxes, remember that heavy items should be placed on the bottom layer. This tip will help you create a stable base with a lower center of gravity. It also helps you avoid crushing any lighter, less-dense goods.

Tip 2: Up to the edge, not over

For maximum stability and pallet density, arrange your boxes in a way that brings them as close to the edges of your pallet as possible without hanging over. Bringing your boxes to the edge makes strapping goods down easier and more stable. Stacking this way also ensures you’re using as much space as possible. Any boxes or goods that overhang are more likely to be damaged or compromise overall stability. Overhanging goods can also cause automatic pallet dimensioners used by carriers to record larger length or width measurements, which can result in freight re-bills or reclassification fees.

Tip 3: Lay boxes like you’d lay bricks

If possible, stack boxes in an overlapping brick pattern. This usually works best if you’re stacking boxes of the same size on your pallet. If unable to use the overlapping pattern, make sure you rotate each new layer of boxes you add. Examples of both patterns can be seen below. Whatever you do, avoid stacking boxes in columns with all the boxes facing in the same direction as this makes it easier for boxes to tip over or slide during transit.

Overlapping Brick

Pallet Packing Illustrations 01 How to Pack Your Pallet: 7 Techniques to Improve Pallet Density & Stability

Rotated Layers

Pallet Packing Illustrations 02 How to Pack Your Pallet: 7 Techniques to Improve Pallet Density & Stability

Tip 4: Avoid the pyramid

When stacking, many shippers make the mistake of placing smaller boxes toward the top of the pallet, causing the stack to narrow as it gets taller. This pyramid shape can compromise the structural integrity of your stack. If possible, work the smaller boxes into the stack so that the overall composition is a more cubic shape.

Pallet Packing Illustrations 03 How to Pack Your Pallet: 7 Techniques to Improve Pallet Density & Stability

Tip 5: Strap up

Before wrapping your freight in shrink or stretch wrap, you’ll want to strap your freight to the pallet using heavy-duty packing bands made from steel, polypropylene, rayon or polyester. Fasten your freight to the pallet using at least two straps on each side as shown below. You can also use cardboard corner boards and slip sheets for more stability.

Pallet Packing Illustrations 04 How to Pack Your Pallet: 7 Techniques to Improve Pallet Density & Stability

Tip 6: Don’t skimp on shrinkwrap

Shrinkwrap secures stacked boxes on pallets, consolidating them into a single unit. If wrapping pallets by hand, tie the end of the shrink wrap to a pallet corner, then wrap from bottom to top. Include the bottom row of boxes, along with about three inches of the pallet, in your first three to four passes around the freight. As you move up the stack, wrap each new row twice, then overlap another three inches at the top. Fold the excess over the top surface. Finally, make four more passes around the middle to bottom part of the stack before cutting the wrap.

Note: If you typically wrap more than a dozen pallets per day, it may make sense to invest in a pallet wrapper. They can wrap a pallet in far less time and with greater consistency than most people can manage. They’ll also spare your back from all the bending over it takes to wrap by hand!

Tip 7: Plan ahead and rethink if necessary

The most important thing you can do to improve the way you pack pallets is to consider all your stacking options. Many companies pack their goods in boxes of a few different sizes. Before packing your next pallet, make a list of all the common box sizes your company ships, then design different packing templates for all the possible stack combinations. Make a template for boxes of all the same size, then another template for boxes of two different sizes, then three different sizes, and so on.

It may also pay to rethink the way you package and box goods. If you can ultimately reduce the amount of packing materials being used and/or use more boxes of a similar size, you may find it easier to pack pallets with better stability, strength and density.

 

For more articles like this, subscribe to our newsletter!

Was this article helpful?

Subscribe to our Blog

Stay up to date with our latest news, receive exclusive deals, and more.

2023 Newsletter Subscription Contact Form

Subscribe to Our Blog

Stay up to date with our latest news, receive exclusive deals, and more.

Any time you add a new piece of equipment or software to your operation, there’s potential for disruption, confusion, and even pushback from employees toward the new device or system. It’s only natural as people don’t like change – especially in the workplace. The good news is, these changes don’t...

We all know things were different before COVID-19. Our lives, our businesses, and even the economy were disrupted by the pandemic, and it made us adapt to what many call a “new reality”. This new reality means that globally, businesses need to navigate disruptions in the supply chain and labor...

Companies are always looking for ways to cut costs and run lighter; and reducing packaging waste is one area where many companies can improve. When you reduce packaging waste, in most cases, you’re also shrinking the footprint of your freight, which helps you save space in your warehouse or distribution...

Wasted space means wasted money. As a warehouse manager, improper pallet sizes can rob you of valuable storage capacity, limiting inventory volumes and operational efficiency. But with some strategic planning, you can optimize your pallet dimensions to maximize usable cubic space. Here at FreightSnap, we help companies right-size their pallets...

In the rapid world of logistics and freight management, identifying leaders in innovation is crucial. Enter FreightSnap, your solution to warehouse automation and optimization. The FreightSnap Image Station, a groundbreaking development in automated freight documentation, is redefining the game for shippers and carriers. Join us on an exciting journey as...

In the fast-paced, fiercely competitive logistics industry, the demand for warehouse automation is more pronounced than ever....

Wasted space means wasted money. As a warehouse manager, improper pallet sizes can rob you of valuable storage capacity, limiting inventory volumes and operational efficiency. But with some strategic planning, you can optimize your pallet dimensions to maximize usable cubic space. Here at FreightSnap, we help companies right-size their pallets...

Subscribe to our Blog

Stay up to date with our latest news, receive exclusive deals, and more.

Reverse Logistics is a type of supply chain management that moves goods from customers back to the sellers or manufacturers. These companies are becoming more and more important every day to help other companies make the most out of their assets and turn them into profit. A reverse logistics company...

Part of protecting your investment is documenting the condition of your freight before it’s shipped....

If you’ve ever shipped anything through a less-than-truckload carrier, you’ve undoubtedly encountered the term “freight class.” And if you’re like a lot of shippers, you might only have a partial understanding about what freight class actually is. To help clear up the picture, we’re going to explain freight class, show...

So, how can we maximize efficiency inside the warehouse? These five ideas are a great place to start....

In the rapid world of logistics and freight management, identifying leaders in innovation is crucial. Enter FreightSnap, your solution to warehouse automation and optimization. The FreightSnap Image Station, a groundbreaking development in automated freight documentation, is redefining the game for shippers and carriers. Join us on an exciting journey as...

In the fast-paced, fiercely competitive logistics industry, the demand for warehouse automation is more pronounced than ever....

Wasted space means wasted money. As a warehouse manager, improper pallet sizes can rob you of valuable storage capacity, limiting inventory volumes and operational efficiency. But with some strategic planning, you can optimize your pallet dimensions to maximize usable cubic space. Here at FreightSnap, we help companies right-size their pallets...

Product Sheet - FS Parcel Dimensioner

2023 DimReimag LP - FSParcel PS Dwnld

Product Sheet - FS 5000 Dimensioner

2023 DimReimag LP - FS500 PS Dwnld

Request a Quote!

2023 DimReimag LP Pricing Request Form