Learn how to stack, wrap and secure cartons for forklift handling. Compare solid wood, plywood and plastic pallets and measure the finished load before booking.
English female narration with English captions
Twelve cartons arriving loose mean twelve separate lifts and twelve pieces to count at each handover. On a pallet they can travel as one handling unit. The shipper still records twelve cartons on the packing list, but the warehouse can scan one pallet ID, move the group in one operation and check that all twelve belong together. Securing the cartons reduces the chance of boxes shifting, colliding or going missing between handling points.
Ask the carrier and consignee about accepted pallet sizes, maximum loaded height and gross weight, forklift access and whether the load can be stacked. A distribution centre that scans one pallet at a time may require pallet labels and a carton count on each unit. For a few small parcels going to a home without unloading equipment, a parcel service may fit better. Agree on the handling unit while you can still change the plan.
Inspect the empty pallet for cracked boards, protruding nails and damaged feet. Use a base that supports the full footprint. Place heavier, stronger cartons low, distribute the weight across the deck and keep carton edges inside it. Follow the carton maker’s stacking limits and orientation marks. A fragile carton can still collapse underneath a well-wrapped load.
Hold the cartons together with suitable stretch film and anchor the load to the pallet. A sleeve wrapped only around the top half can leave the whole stack free to slide off the base. Use corner protection where the film might tear against an edge. Leave the fork openings clear and keep handling labels readable.
Choose bands, edge protectors or another suitable restraint for the goods and the journey. Route bands through the pallet’s intended load-bearing structure. Protect soft carton edges and adjust tension to avoid crushing them. Heavy equipment, off-centre items and fragile loads may need a purpose-built base, blocking or a crate. Ask the packing team to specify the restraint before collection.
Check that the load is stable and the fork entries are clear. A trained operator should use equipment rated for the complete palletized load. Record the pallet ID, carton count, gross weight and outside dimensions. Give the receiver any stacking restrictions and the information needed to unload. Keep people clear of the operating area.
Compare pallets of the same footprint. Ask the supplier for the load rating under the actual handling and storage conditions.
A timber pallet with the right design and load rating is a common choice for heavier freight. Boards and runners can be inspected individually. Ask for the weight limit for the way the pallet will be used, whether on a floor, moving on forks or bridging rack beams. For an international shipment, check the destination’s requirements for raw wood packaging and any separate wooden blocking.
Some plywood designs reduce the weight of the empty pallet. Compare their actual tare weight and rated capacity at the same footprint. A pallet made wholly from qualifying processed wood such as plywood is generally exempt from ISPM 15. Check underneath the deck. Solid wood blocks, feet or runners can bring those components within the standard.
A suitable plastic pallet resists moisture and can be washed between trips. On a repeat route, compare its purchase price and return costs against the number of trips you expect to recover it for. Check its rating for racks and for moving loads. A plastic base falls outside the raw wood scope of ISPM 15. Any wooden dunnage added to the shipment still needs its own check.
Suppose twelve packed cartons weigh 10 kg each. The empty pallet weighs 15 kg and the wrap, straps and protectors add 1 kg. The gross weight for this handling unit is 136 kg. If the loaded pallet measures 120 × 100 × 110 cm at its outermost points, it occupies 1.32 m³. Measure from the floor to the highest point and include the pallet in the height. Enter the finished dimensions and gross weight when comparing services. The carrier’s pricing rules determine the chargeable weight.
List the materials in the deck, blocks, runners and loose packing. For regulated raw wood, confirm that an authorized provider applied an approved treatment and the required IPPC mark. Heat treatment and fumigation are different options. Ask the importer about the destination’s conditions, take clear photos of the marks before wrapping, and keep them with the shipment record. Confirm cleanliness, packaging declarations and receiving rules separately for the route.
Read the wood packaging guide →
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