How to Palletise Your Goods

Palletising your goods correctly is the single most important step you can take to ensure they arrive safely at their destination. Poorly palletised shipments are more likely to suffer damage during transit, and they can also cause delays if they do not meet the pallet network's standards for safe handling.

This guide walks you through the entire process, from choosing the right pallet to applying the final label. Whether you are shipping one pallet or fifty, these steps will help you prepare your goods to the standard expected by UK pallet carriers.

The standard pallet size used across the UK pallet network is 1200mm x 1000mm (approximately 4 feet by 3 feet 3 inches). This is sometimes referred to as a UK standard pallet or a GMA pallet. Most carriers are set up to handle this size, and using it ensures your pallet moves smoothly through the network without delays.

You can also use euro pallets (1200mm x 800mm) on most services, but check with us first as pricing may differ. Non-standard pallet sizes may incur additional charges or require special arrangements.

What to Look For in a Good Pallet

• Structurally sound: All deck boards should be intact with no cracks, splits, or missing sections. The pallet must be able to bear the weight of your goods without flexing or bowing.
• No protruding nails: Check for nails that have worked loose or are sticking out. These can damage your goods or other pallets during transit, and they are a safety hazard for handlers.
• Clean and dry: Avoid pallets that are visibly dirty, contaminated with chemicals, or damp. Moisture can transfer to your goods and cause damage during a multi-day journey.
• Four-way entry: The pallet should have openings on all four sides so that a forklift or pallet truck can lift it from any direction. This makes handling at hubs and depots much easier.

How you stack your goods on the pallet has a major impact on stability during transit. Pallets are moved by forklift, loaded onto trailers, and transported across the motorway network. Your load needs to withstand being tilted, vibrated, and moved alongside other pallets.

The Golden Rules of Stacking

Stretch wrapping (sometimes called shrink wrapping, though technically they are different processes) is essential for holding your goods together and attaching them firmly to the pallet. Properly wrapped pallets are dramatically less likely to suffer shifting or damage during transit.

How to Apply Stretch Wrap

1. 1

   Start at the base. Anchor the wrap to one corner of the pallet at the bottom. Wrap around the base of the pallet two or three times, ensuring you are covering the junction between the goods and the pallet itself. This anchors everything to the pallet.

2. 2

   Work upwards in a spiral. Move the wrap upwards in a spiral pattern, overlapping each layer by about 50%. This overlap is important as it doubles the thickness of the wrap at every point, providing much greater strength.

3. 3

   Cover the top. When you reach the top of the load, fold the wrap over the top edge and continue wrapping downwards for at least two full rotations. This prevents water ingress and provides extra stability.

4. 4

   Apply at least three full layers. For most shipments, you should apply a minimum of three complete layers of stretch wrap from bottom to top. For heavy or valuable items, consider four or five layers.

5. 5

   Keep tension consistent. Apply the wrap with firm, even tension. Too loose and it will not hold anything in place. Too tight and it may crush softer items or cause boxes to buckle. You want the wrap to feel taut but not strained.

When to Use Corner Boards

Corner boards (also called edge protectors) are L-shaped cardboard or plastic strips that sit on the vertical corners of your pallet. They serve two purposes: they protect the corners of your goods from impact damage, and they distribute the pressure of the stretch wrap more evenly, reducing the risk of crushing.

We strongly recommend corner boards for any shipment containing fragile items, any pallet taller than one metre, and any load where the outer boxes are not strong enough to bear the compression of multiple layers of stretch wrap. They cost very little and can prevent costly damage.

Correct labelling is essential. Your pallet will pass through multiple handling points, from the collection driver to the hub sorters to the delivery driver. Every person who handles your pallet will rely on the label to know where it needs to go.

What to Include on Your Label

• Your booking reference number (e.g. PD12345678). This is the most important piece of information and should be clearly visible.
• Delivery address including the full postcode. The postcode is used for routing at every hub in the network.
• Collection address so the pallet can be returned if there is a problem with delivery.
• Contact telephone numbers for both the sender and recipient, in case the driver needs to call about access or delivery instructions.
• Number of pallets in the consignment if you are sending more than one (e.g. "Pallet 1 of 3").

Where to Place Your Labels

Attach labels to at least two adjacent sides of the pallet, at eye level (roughly one metre from the ground). Place labels on the outside of the stretch wrap so they are clearly visible. Do not place labels on the top of the pallet where they may be obscured if another pallet is stacked on top.

Use a clear adhesive pouch or tape the label securely so it will not peel off during transit. If you are using the shipping labels from your pallets.delivery booking confirmation, print them on A4 paper and attach with clear packing tape.

Handling Instructions

If your goods require special handling, mark this clearly on the pallet. Use standard handling symbols where possible: "FRAGILE", "THIS WAY UP" (with arrows), "DO NOT STACK", or "KEEP DRY". Write these in large, bold letters with a permanent marker or use pre-printed handling labels. Place them on all visible faces of the pallet.

For pallets weighing more than 500kg or standing taller than 120cm, stretch wrap alone may not provide sufficient stability. In these cases, you should use additional securing methods to keep your load safe during transit.

Pallet Strapping

Polypropylene or polyester strapping can be applied over the stretch wrap to add rigidity. Run at least two straps vertically over the top of the pallet and down through the pallet base, then tension them with a strapping tool or ratchet mechanism. For wide loads, add horizontal straps around the middle and top of the stack.

Ratchet Straps

For very heavy or awkwardly shaped items, ratchet straps provide the strongest hold. Thread the strap through the pallet base, over the top of the goods, and back through the other side. Tighten until firm but not so tight that you are crushing the goods. Two straps in a cross pattern provides excellent stability.

Top Caps and Sheets

A corrugated cardboard top cap placed on top of your load before wrapping provides additional crush protection. It distributes the weight of any pallet stacked above yours across the full surface area rather than concentrating it on individual boxes. We recommend top caps for any pallet that is shorter than 120cm as these are most likely to have another pallet placed on top during transit.

Final Checklist Before Collection