How to pack a pallet correctly: heavy goods at the bottom, cartons stacked flush and without overhang, edges protected, the load firmly bound to the pallet with stretch film and strapped if necessary. Good load securing on the pallet prevents goods from slipping, tipping over or being crushed during handling. This article shows step by step what matters and what to do if damage still occurs.
How to pack a pallet: choosing the right pallet
The basis of every shipment is an intact pallet. In European transport, the Euro pallet measuring 120 × 80 × 14.4 cm is the standard. A Euro pallet can carry up to 1,500 kg when the load is evenly distributed.
- Only use pallets without broken boards, missing blocks or protruding nails.
- Goods must not overhang the edge of the pallet. Overhang leads to damage during handling and takes up more space in the truck.
- For larger goods, other formats are available, such as industrial pallets measuring 120 × 100 cm. Always state the format when booking.
You can read more about dimensions and variants in our blog.
Stacking patterns and weight distribution
How you arrange the cartons on the pallet determines the stability and load capacity of the load.
Column stacking
With column stacking, each carton sits exactly on top of the one below. The corners and edges of the cartons therefore carry the full load. This arrangement makes the best use of the cartons' compression strength, but it is less stable sideways. It therefore needs good securing with film or strapping.
Interlocking stacking
With interlocking stacking, each layer is offset from the one below, similar to a brick wall. The layers interlock and the load holds together better. In return, the cartons carry less weight because their edges are not aligned. For light goods, interlocking is often the better choice. For heavy goods, column stacking with good securing is better.
Distributing weight correctly
- Heavy packages go at the bottom, light ones at the top.
- Distribute the weight evenly over the entire surface. The centre of gravity should be as central and as low as possible.
- Avoid gaps between cartons. Fill empty spaces with void fill or layer pads.
- The top layer should be as flat as possible. A cover board made of cardboard or wood distributes the pressure if the pallet is stacked.
Edge protectors, stretch film and strapping
These three materials bind the goods and the pallet into a solid unit. How much of each is needed depends on the weight, shape and fragility of the goods.
Edge protectors
Edge protectors made of cardboard or plastic are placed vertically at the four corners of the load. They distribute the pressure of the strapping bands, stabilise the corners and protect the cartons from impacts by forklifts. When strapping is used, edge protection almost always makes sense.
Stretch film
- Start at the bottom and wrap the first layers around the base of the pallet. This way, the film binds the goods to the pallet and not just the cartons to each other.
- Wrap upwards with a clear overlap between the layers, roughly half the width of the film.
- If necessary, place a top sheet or cover sheet on the load before wrapping the upper layers. This protects against dust and moisture.
- Pull the film tight, but not so tight that light cartons are crushed.
Strapping
Strapping bands made of plastic such as PET or of steel hold heavy or compact loads together. Pass the bands through the pallet so that they bind the goods and the pallet together. Two bands in each direction are a good guideline for heavy goods. Steel bands are suitable for very heavy goods, but they always need edge protection.
Common securing mistakes
- Film only around the cartons: If the base of the pallet is not wrapped, the entire load slides off the pallet when braking or lifting.
- Too little film for heavy goods: A few loose layers cannot hold a heavy load. More layers and additional strapping help.
- Strapping without edge protection: The bands cut into the cartons and damage the goods.
- Cartons with overhang: If goods protrude beyond the edge, they get knocked during loading and crushed during stacking.
- Half-empty cartons: They give way under load and tilt the entire pallet. Fill the empty spaces.
Stackability and maximum height
Whether your pallet is stackable is one of the most important details when booking. It affects both price and safety.
- Stackable: Another pallet can be placed on top of yours without damaging the goods. For this, the top must be flat and able to bear weight.
- Non-stackable: The goods cannot bear any load from above, for example sensitive equipment or irregular shapes. In this case, mark the pallet clearly, for example with a notice or a cone on top.
There is no uniform height limit. Many groupage networks have maximum values including the pallet, and pallets with a greater height are charged differently or not accepted. Check the requirement before booking and always measure the height including the pallet. Non-stackable pallets are usually charged at a higher rate because the space above them remains unused. You can read more about pallet shipping costs in our blog.
Marking and labels
During handling, it must be possible to identify a pallet at a glance. Missing labels lead to misrouting and delays.
- Attach the shipping label to at least two opposite sides, not to the top.
- The label contains the sender, recipient, shipment number and the number of packages, for example "Pallet 1 of 3".
- Stick labels onto the film or protect them with clear pouches so that they are not covered during wrapping.
- Mark special requirements with common symbols, such as "This way up", "Fragile" or "Do not stack".
- Tilt and shock indicators help with sensitive goods. They show whether the pallet was tipped or hit hard in transit.
- Dangerous goods have their own marking regulations. Clarify these before shipping.
Documentation before collection
Good documentation helps you if there is a dispute about damage later. It only takes a few minutes.
- Photograph each pallet from all four sides and from above once it is fully secured.
- Take close-ups of labels, edge protectors and strapping.
- Note the weight and dimensions of each pallet. If the details in the booking are correct, you avoid additional charges.
- Check that the number of pallets, the delivery note and the consignment note match.
- Have the driver confirm receipt on the consignment note. For international road transport, this is the CMR consignment note.
Legally, the sender is responsible for packaging that is safe for transport, regulated in German law in § 411 HGB (German Commercial Code). If the goods are damaged due to poor packaging, the carrier is generally not liable.
What to do in case of transport damage
Even well-packed goods can be damaged. What matters most then is that you react quickly and correctly.
On delivery
- On delivery, check the pallets for external damage, damaged film, crushed cartons and the number of pallets.
- Note visible damage immediately and specifically on the consignment note or delivery note, for example "Pallet 2: film torn, two cartons crushed". A general note such as "subject to inspection" is usually not enough.
- Have the driver countersign the note and photograph the damage.
Concealed damage
If damage only becomes apparent when unpacking, you must report it in writing. Under the HGB and the CMR, the deadline is seven days after delivery, excluding Sundays and public holidays under the CMR. Keep the packaging and the damaged goods until the damage has been settled.
The damage report
Report the damage with photos, the consignment note with the remark, the delivery note, the invoice for the value of the goods and a description. Under the HGB and the CMR, the carrier's statutory liability is limited to 8.33 Special Drawing Rights per kilogram of gross weight. For valuable goods, additional transport insurance is therefore worthwhile.
Frequently asked questions
How high can a pallet be loaded?
That depends on the network and the provider. Many groupage networks have maximum values including the pallet. Check the requirement before booking and state the actual height.
Is stretch film enough to secure the load on a pallet?
For light, uniform cartons it often is, provided the film includes the base of the pallet and is wrapped tightly. Heavy or compact loads should also be strapped and fitted with edge protectors.
Who is liable if a poorly packed pallet is damaged?
The sender is responsible for packaging that is safe for transport. If the damage is caused by inadequate packaging, the carrier is generally not liable.
How quickly do I have to report transport damage?
Visible damage must be noted on the consignment note immediately on delivery. Concealed damage must be reported in writing within seven days of delivery.
Is your pallet ready to ship? In the price calculator you can see the fixed price for your pallet shipment instantly and without an account.