Packing a pallet correctly means: placing heavy items at the bottom, stacking boxes flush and without any overhang, protecting the edges, securing the load firmly to the pallet with stretch film, and strapping it if necessary. Proper load securing on the pallet prevents goods from shifting, tipping over, or being crushed during handling. This article provides a step-by-step guide to what matters most and what to do if damage occurs despite these precautions.
Choosing the Right Palette
The foundation of every shipment is an undamaged pallet. In European transport, the standard Euro pallet measures 120 × 80 × 14.4 cm. A Euro pallet can hold up to 1,500 kg when the load is evenly distributed.
- Use only pallets that do not have broken boards, missing blocks, or protruding nails.
- The goods must not extend beyond the edge of the pallet. Any overhang can cause damage during handling and takes up more space in the truck.
- For larger items, there are other sizes available, such as industrial pallets measuring 120 × 100 cm. Always specify the size when making a reservation.
For more information on dimensions and variants, see the article " Euro Pallet Dimensions."
Stacking Patterns and Weight Distribution
The way you arrange the boxes on the pallet determines the stability and load-bearing capacity of the shipment.
Column Stacking
When stacking boxes in columns, each box rests directly on top of the one below it. This way, the corners and edges of the boxes bear the full load. This arrangement makes the best use of the boxes’ compressive strength but is less stable on the sides. It therefore requires secure fastening with plastic wrap or strapping.
Composite Stacking
In interlocking stacking, each layer is stacked offset from the one below it, similar to a wall. The layers interlock, holding the load together more securely. However, the boxes bear less weight because their edges do not rest on top of one another. For light goods, interlocking stacking is often the better choice; for heavy goods, column stacking with secure fastening is preferable.
Distribute Your Weight Properly
- Heavy packages should go on the bottom, and light ones on top.
- Distribute the weight evenly across the entire surface. The center of gravity should be as close to the center and as low as possible.
- Avoid leaving gaps between the boxes. Fill any empty spaces with packing material or dividers.
- The top layer should be as level as possible. A cover plate made of cardboard or wood helps distribute the pressure when the pallet is stacked.
Edge protection, stretch film, and strapping
These three methods secure the goods to the pallet, forming a single, stable unit. The amount needed depends on the weight, shape, and fragility of the goods.
Edge Protection
Corner protectors made of cardboard or plastic are placed vertically at the four corners of the load. They distribute the pressure from strapping bands, stabilize the corners, and protect the boxes from impacts by forklifts. Corner protectors are almost always useful when strapping a load.
Stretch film
- Start at the bottom and wrap the first few layers around the base of the pallet. This way, the wrap secures the cargo to the pallet, rather than just holding the boxes together.
- Wrap upward, ensuring that the strips overlap significantly—about half the width of the film.
- If necessary, place a cover sheet or cover sheet of paper on top before wrapping the top layers. This protects against dust and moisture.
- Pull the plastic wrap taut, but not so tightly that it dents lightweight cardboard boxes.
Strapping
Strapping made of plastic, such as PET, or steel holds heavy or compact loads together. Thread the straps through the pallet so that they secure the goods to the pallet. Two straps in each direction is a good guideline for heavy goods. Steel straps are suitable for very heavy goods but absolutely require edge protection.
Common Mistakes When Backing Up
- Wrap the plastic only around the boxes: If the base of the pallet isn't wrapped, the entire load will slide off the pallet when braking or lifting.
- Insufficient plastic wrap for heavy goods: A few loose layers won't hold a heavy load. More layers and additional strapping will help.
- Strapping without edge protection: The straps cut into the boxes and damage the goods.
- Boxes with protruding contents: If goods protrude beyond the edge, they will be bumped during loading and crushed during stacking.
- Half-empty boxes: They give way under weight and cause the entire pallet to tilt. Fill in any empty spaces.
Stackability and Maximum Height
Whether your pallet is stackable is one of the most important pieces of information when making a reservation. It affects both the price and safety.
- Stackable: You can place another pallet on top of your pallet without damaging the goods. To do this, the top surface must be flat and sturdy.
- Not stackable: The goods cannot support a load from above, such as in the case of fragile equipment or irregularly shaped items. In this case, clearly mark the pallet, for example with a label or a cone on top.
There is no standard height limit. Many general cargo networks have maximum height limits that include the pallet, and pallets that exceed these limits are charged differently or may not be accepted. Check the specifications 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. For more information, see the article “Pallet Shipping Costs.”
Markings 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 on the top.
- The label includes the sender, recipient, tracking number, and the number of packages, for example, “Pallet 1 of 3.”
- Stick labels onto the film or protect them with clear sleeves so they aren't covered up when you wrap it.
- Label any special features using standard symbols, such as “This Side Up,” “Fragile,” or “Do Not Stack.”
- For fragile goods, tilt and shock indicators are helpful. They show whether the pallet has been tilted or subjected to a hard impact during transport.
- Hazardous materials are subject to their own labeling regulations. Be sure to clarify these before Shipping.
Documentation Before Pickup
Good documentation will help you if a dispute arises later regarding damage. It only takes a few minutes.
- Once each pallet has been properly secured, take photos of it from all four sides and from above.
- Take close-up photos of labels, edge protectors, and strapping.
- Record the weight and dimensions of each pallet. If the information in the entry is correct, you’ll avoid having to make adjustments later.
- Please verify that the number of pallets matches the delivery note and the bill of lading.
- Have the driver sign the waybill to confirm receipt. For international road transport, this is the CMR waybill.
Legally, the shipper is responsible for ensuring that the packaging is suitable for transport, as stipulated in Section 411 of the German Commercial Code (HGB). If the goods are damaged due to poor packaging, the carrier is generally not liable.
What to Do in Case of Damage During Shipping
Even well-packaged goods can be damaged. In that case, it’s especially important that you respond quickly and appropriately.
Upon delivery
- Upon delivery, inspect the pallets for external damage, damaged plastic wrap, dented boxes, and the quantity.
- Immediately note any visible damage in specific terms on the bill of lading or delivery slip; for example, “Pallet 2: plastic wrap torn, two boxes dented.” A general note such as “subject to inspection” is usually not sufficient.
- Have the driver sign the report and take a photo of the damage.
In the case of hidden damage
If damage is not discovered until you unpack the item, you must report it in writing. According to the German Commercial Code (HGB) and the CMR, you have seven days after delivery to do so; under the CMR, this period excludes Sundays and holidays. Keep the packaging and the damaged goods until the matter has been resolved.
The Damage Report
Report the damage by providing photos, a waybill with a note, a delivery receipt, an invoice showing the value of the goods, and a description. Under the German Commercial Code (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, it is therefore advisable to take out additional cargo insurance.
Frequently Asked Questions
What is the maximum load capacity of a pallet?
That depends on the network and the carrier. Many general cargo networks have maximum weight limits that include the pallet. Check the specifications before booking and enter the actual weight.
Is stretch wrap sufficient for securing cargo on a pallet?
For light, uniform cartons, the answer is often yes, provided the film covers the base of the pallet and is wrapped tightly. Heavy or compact loads should also be strapped and fitted with corner protectors.
Who is liable if a poorly packaged pallet is damaged?
The shipper is responsible for ensuring that the shipment is properly packaged for transport. If damage results from inadequate packaging, the carrier is generally not liable.
How soon do I need to report damage that occurred during shipping?
Visible damage must be noted on the waybill immediately upon delivery. Hidden damage must be reported in writing within seven days of delivery.
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