32. Pallet Types and Sizes
The Foundation of Material Handling and Efficient Logistics
What Is a Pallet?
A pallet is a flat, rigid platform used as a base for assembling, storing, handling, and transporting goods. It allows products to be moved efficiently with forklifts, pallet jacks, and conveyors, and is a fundamental unit in both warehousing and shipping.
Pallets serve as the standard interface between unit loads and material handling equipment, enabling efficient unitization — grouping goods into a single, stable load.
Why Pallets Matter in Logistics
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Standardization: Pallets standardize cargo dimensions, simplifying storage and transport.
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Efficiency: Enable faster loading/unloading of goods.
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Protection: Keep goods off the ground and reduce damage from handling.
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Space Optimization: Facilitate vertical stacking in warehouses.
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Compatibility: Match container, truck, and warehouse dimensions for optimized use of space.
Standard Pallet Sizes by Region
| Region | Standard Size (mm) | Size (inches) | Notes |
|---|
| Europe (EUR/EPAL) | 1200 × 800 | 47.2 × 31.5 | Known as the Euro pallet (EPAL 1) |
| North America | 1219 × 1016 | 48 × 40 | Referred to as GMA pallet (Grocery Mfrs. Assoc.) |
| Asia (ISO) | 1100 × 1100 | 43.3 × 43.3 | Popular in Japan, Korea, and China |
| Australia | 1165 × 1165 | 45.9 × 45.9 | Compatible with Australian racking systems |
| UK (obsolete) | 1200 × 1000 | 47.2 × 39.4 | Being replaced by Euro pallets in many cases |
Note: ISO 6780 outlines six standard pallet dimensions to harmonize global trade.
Common Pallet Types by Material
1. Wooden Pallets
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Most widely used and economical.
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Can be two-way or four-way entry (forklift can access from 2 or 4 sides).
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Subject to ISPM-15 treatment for international shipping (heat-treated or fumigated to prevent pests).
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Repairable and recyclable.
2. Plastic Pallets
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Hygienic (resistant to moisture, chemicals, mold).
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Ideal for pharmaceuticals and food industries.
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Durable, reusable, but more expensive.
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Lightweight and consistent in size/shape.
3. Metal Pallets (Steel/Aluminum)
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Used in heavy-duty or hazardous material handling.
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High durability, fire-resistant, and long lifespan.
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Expensive and heavier than other options.
4. Paper/Cardboard Pallets
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Lightweight, recyclable, and suited for air freight to reduce costs.
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Single-use or short-term use only.
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Low load-bearing capacity.
Pallet Construction Styles
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Stringer Pallet: Uses three or more parallel timber boards (stringers); can be notched for four-way entry.
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Block Pallet: Uses blocks instead of stringers; offers true four-way access.
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Double-Face Pallet: Deck boards on both top and bottom for added strength and stackability.
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Wing Pallet: Deck boards extend beyond stringers for extra support or easier lifting.
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Nestable Pallet: Usually plastic, designed to stack inside one another when empty to save space.
Pallet Entry Types
Load Capacity of Pallets
| Pallet Type | Static Load* | Dynamic Load** | Racking Load*** |
|---|
| Wood (standard) | ~3000 kg | ~1000–1500 kg | ~1000 kg |
| Plastic (HDPE) | ~1500–3000 kg | ~1000–1200 kg | ~800–1000 kg |
| Steel | ~4000+ kg | ~1500–2000 kg | ~1500+ kg |
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Static Load: Maximum weight a pallet can handle while at rest.
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Dynamic Load: Max weight during movement (e.g. on a forklift).
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*Racking Load: Max weight when pallet is placed in a rack system with no support beneath.
Special Pallet Features
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Anti-slip surfaces or mats to stabilize slippery loads.
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Reinforced corners or edges for load security.
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Ventilated decks for products that need airflow.
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RFID or barcodes embedded for tracking.
Best Practices in Pallet Handling
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Uniform load distribution is essential to avoid tipping or breakage.
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Use stretch film or strapping to secure goods.
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Avoid overhanging product, which increases risk of damage.
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Inspect pallets regularly for splinters, cracks, or protruding nails.
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Store in dry conditions to avoid mold or wood degradation.
Summary
Pallets are the unsung heroes of logistics. Their standardization, versatility, and strength make them critical tools in warehousing, transportation, and inventory management. Choosing the right pallet — in terms of size, material, and design — can dramatically improve operational efficiency, cost control, and product safety throughout the supply chain.
