How to Properly Load Pallets

Jan 03, 2024

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a man is pushing a properly loaded pallet with boxes on it in a warehouse.

Pallets are an inherently safe, stable way to transport a wide variety of goods and other items - but they are not infallible. An incorrectly loaded pallet isn't just a waste of time and energy. It actually leaves you in a situation that is arguably more dangerous and likely to cause damage to items during shipping than the one you were in when you started.

Thankfully, properly loading pallets isn't necessarily difficult - but you do have to treat every situation that you're dealing with as unique.

Consider Box Sizes

The size of the boxes that you're working with will always be an essential factor in determining what size and type of pallet you need. Under no circumstances should the boxes themselves become an afterthought. For the sake of convenience, start by arranging all your boxes not by what is in them, but by their size and shape, so you can see exactly what you're dealing with.

Stacking Techniques

It's also important to note that there are several stacking techniques to choose from, depending on your needs. Again - every situation is different, so never assume there is a "one size fits all" approach to stacking pallets.

Stack by Weight

Another essential tip involves taking weight into consideration when making stacking decisions. Always place the heavier boxes on the base layer, creating a stable foundation upon which everything else can be built. This will help prevent damage to the lighter boxes, reduce the risk of anything tipping over in transit, and improve stability as well.

Matching Box Sizes

Remember that not all pallets are created equally. Always make sure that the box sizes match the pallet dimensions that you're working with. Don't start with a pallet and stack whatever boxes are near for the sake of convenience. Always make sure no part of the box is hanging over the edge of the pallet, which can and likely will cause damage during shipping.

Use the Bricklaying Method

Finally, consider what is commonly referred to as the "Bricklaying Method." Here, you'll stack uniform boxes in a bricklaying pattern, which will help you securely tie them in.

a man is loading boxes onto a wooden pallet.

As the boxes become interlocked, they essentially act as a collective. This makes individual boxes less likely to shift during transit, creating much safer transportation along the way.

Wrap and Secure the Load

At this point, you can use a pallet wrapping material to safely wrap and secure the pallet before it is ready for final transportation. Always use at least one layer of wrap and make sure that every box on the pallet is included, regardless of how safe the ones at the bottom may initially seem. This will help keep the overall weight of the pallet in the center, where it belongs. This will help significantly reduce the likelihood that anything will shift, tip over, or get damaged during the shipping process.

If you'd like to find out more information about how to properly load pallets, or if you'd just like to discuss your own needs with someone in a bit more detail, please feel free to contact Advance Pallet today.