Parcels Grow Up Into Pallets
When you move B2B, wholesale, or inbound to a 3PL, packaging includes the unit load. A perfect carton still fails if the pallet leans like a tired cake.
description: "Build safer unit loads: pallet types, stacking patterns, stretch wrap, edge boards, load height, and when to use straps or corner protection."
order: 21
schemaType: "Article"
navLabel: "Palletization"
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Pallet Choices
- GMA / standard regional pallets: Match destination norms
- Block vs stringer: Handling equipment compatibility
- Heat-treated / ISPM-15: Export requirements
- Chep/PECO pools: Rental networks vs white-wood purchase
Broken pallets create crush from below — inspect before build.
Stacking Patterns
Column stacks maximize compression strength when cartons align; interlocking can help stability but may reduce ECT performance. Do not mix crush-sensitive flutes at the bottom with dense goods up top without maths.
Keep labels scannable on two sides. Avoid overhang — overhang murders board edge strength (corrugate).
Containment
| Method | Role |
|---|---|
| Stretch wrap | Unitize; choose gauge/wrap count for weight |
| Straps | Heavy loads; protect edges from strap cut-in |
| Corner / edge boards | Vertical strength + strap protection |
| Top sheets / lids | Dust and drizzle; stacking platform |
Wrap tension matters: too loose = walk; too tight = crush light cartons.
Height, Weight, and Safety
Know trailer and racking limits. Keep heavy/low. Train forklift approach so forks do not spear the bottom tier. Photograph standard builds into an SOP — same energy as a pack-bench photo SOP.
Testing Mentality
A tip test, route vibration if you can, and a forklift abuse session in the yard beat theoretical wrap counts. Tie findings to pack testing language even at pallet scale.
Warehouse-Friendly Pallet Rules
- No overhang (or label it and accept damage risk)
- Interlock layers when stretch wrap alone is wishful thinking
- Put crush-sensitive layers on top with a sheet
- Record cases per layer × layers × pallet TI/HI in the WMS
Retailer routing guides override your aesthetic. Read the guide.
Related
Packaging RFQ for pallets/wrap supply · Packaging Metrics for damage in inbound