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How to prepare a pallet for shipping – A Practical Guide

Shipping goods on a pallet can be very efficient and cost-effective, but only if the pallet is prepared correctly. During transport, pallets are handled many times – loaded, unloaded, and moved between trucks and warehouses. Proper preparation greatly reduces the risk of damage and delays. Up to 90 % of common damage can be avoided with correct pallet packing.

General rules for all pallet shipments

Before we look at specific types of goods, there are a few basic rules that apply to every pallet:
 

  • Fit within the pallet edges: Nothing should extend beyond the edges of the pallet. Items shouldn’t stick out or hang over the sides.
  • Correct labeling: The shipping label should be placed in the upper right corner on the short side of the pallet.
  • Stability: A properly packed pallet should stay stable even if tilted at an angle during handling.
  • Secure wrapping: Wrap the goods firmly with stretch film so they form a single unit with the pallet.

Preparing pallet with mixed or heavy goods

When you have many different products or heavy items on one pallet:
 

  • Place heavier items on the bottom and lighter ones on top. This keeps the pallet stable.
  • Fill lower layers completely so there are no gaps or unstable areas.
  • If items are irregular in shape, use sturdy outer boxes or crates to support them.
  • For heavy or bulky items, consider using reinforced crates and strapping for extra strength.
  • If the goods are not easily stacked individually, pack them into aggregate boxes or use mesh baskets or frames before placing them on the pallet.

Tip: Grouping smaller products into one box before putting them on the pallet saves space and reduces movement.

Loose or Bagged Goods

For items in bags (e.g., grains, powders, pellets):

  • Make sure the bags do not extend past the pallet edges.
  • Place them in uniform layers and use sheet material between layers to enhance stability.
  • Keep the total height reasonable (if possible under 1 m) so the pallet remains stable.
  • If the bags cannot be stacked, mark the pallet clearly to indicate this (e.g., with a “do not stack” symbol).

Pallet with goods in buckets, cans, or drums

When packaging goods in containers such as buckets, tins, or metal cans:

  • Place them so protruding parts do not press against or damage neighbouring containers.
  • Use rigid spacers or separators between items to prevent movement.
  • Wrap the pallet in stretch film so the load is secured, but not so tight that lids or seals are crushed.

Pallets with Non-Standard or Fragile Load

Some goods require special care:

  • Oversized pallets (larger than a standard Euro pallet) may need extra stabilization or reinforcement.
  • Fragile or shock-sensitive materials should be placed with protective packaging such as foam, cardboard corner protectors, or wooden supports.
  • If your goods are subject to regulations (e.g., ADR hazardous materials), they must be packed and labeled according to the applicable standards.

Preparing pallet for shipping in 5 steps:
 

STEP 1 - Place goods properly on the pallet: pay attention to the absence of cardboard boxes that protrude beyond the pallet.

STEP 2 - Use extra side protection - for the corners of the goods on the pallet, when the goods can shift, use appropriate product labeling.

STEP 3 -The pallet with the goods should be wrapped in stretch tape: - so that its lower ends overlap the pallet structure; - also wrap the top of the pallet; - fasten free end of the film roll around the supporting part of the pallet; - wrap the stretch film in at least 3 layers.

STEP 4 - Packaging tape additionally wrap stretch tape - to reinforce it so that nothing moves during transportation

STEP 5 - Prepare printed label, advisable to use RABEN system or others using barcodes and complying with the GS1 standard, place it on the short side of the pallet in the upper right corner.

Final packaging tips for all shipments
 

  • Wrap the pallet fully with stretch film, including top and bottom overlaps, so that the cargo cannot shift.
  • Use packaging tape, corner boards, and strapping if necessary to reinforce heavy loads.
  • Ensure the pallet remains stable if tilted or bumped during handling.
  • Clearly mark any special handling requirements, such as “Do Not Stack” or “Fragile.”

Still have questions? Download our graphic guide!

Preparing pallet for shipping

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