When people think of logistics, they think of trucks, containers, ships, or planes. A much smaller component of the transport chain, however, is easily overlooked: the pallet. Yet, choosing the right load carrier can determine how efficiently goods can be stored, loaded, and transported. Dimensions, weight, material, load capacity, and even the destination country all play a role.

Because not all pallets are created equal.

The classic: the Euro pallet

It is likely the most well-known load carrier in Europe: the Euro pallet. The standardized EPAL Euro pallet (EPAL 1)is particularly common. Its dimensions are: 1,200 × 800 × 144 millimeters

It has an empty weight of approximately 25 kilograms, and the safe working load specified by EPAL is 1,500 kilograms. Standardization is one of its greatest advantages. Storage technology, conveyor systems, racking systems, and truck loading areas can all be tailored to defined dimensions. This allows for efficient use of available space and simplifies the handling of goods.

However, not every pallet with dimensions of 1,200 × 800 millimeters is automatically an EPAL Euro pallet. To qualify, it must meet the corresponding technical requirements and be correctly marked.

Industrial pallet: a bit more surface area

In addition to the Euro pallet, you will often encounter pallets in the 1,200 × 1,000 millimeterformat. This larger base size offers more loading area and can be particularly suitable for goods whose packaging might be awkwardly arranged on the narrower Euro pallet.

However, "industrial pallet" is not a single product with an identical design or load capacity. The specific construction and specifications are what matter. EPAL, for example, also offers various load carriers in this size range with differing technical properties.

Therefore, transport planning should not be based on external dimensions alone.

One-way pallet: the name doesn't tell the whole story

There are also so-called one-way pallets. They are frequently used for shipments where no pallet exchange is planned. "One-way" initially means that the pallet does not have to be part of an open exchange system like the EPAL pool. It does not necessarily mean that it must be disposed of after a single transport.

One-way pallets come in various dimensions, designs, and load capacities. They can therefore be specifically adapted to the goods in question. This can be particularly attractive for exports when the pallet is intended to remain at the destination.

Wood or plastic?

Wood is widely used for transport pallets, but it is by no means the only option. Plastic pallets, for example, can be an attractive choice where hygiene, moisture, or recurring standardized processes play a significant role. Weight, service life, cleaning options, and the intended use also influence the decision.

There is therefore no single best pallet. Instead, the right pallet is the one that suits the goods, the transport chain, and the intended application.

When goods overhang the pallet

A common mistake when palletizing is allowing goods to overhang the base of the pallet. This can cause several problems at once. Overhanging boxes or other packaging are less protected against lateral impact. At the same time, the load may take up more floor space than originally calculated.

This is particularly relevant when trying to maximize the efficiency of trucks, containers, or storage areas. The opposite is not automatically optimal either: if a large pallet is only partially used, space is being transported unnecessarily. Good palletizing therefore aims to coordinate goods and load carriers as effectively as possible.

Distributing weight correctly

It is not just the total weight of a pallet that matters; how that weight is distributed is equally critical. Heavy goods should be positioned and secured so that the pallet remains stable and can be moved safely with industrial trucks. Poor weight distribution can compromise stability and make securing the load more difficult.

Furthermore, the permissible load should not simply be estimated based on the size of a pallet. It depends on the design, condition, and specifications of the individual load carrier. For an EPAL Euro pallet, for example, the safe working load is 1,500 kilograms.

The pallet and load securing

A pallet turns individual boxes or components into a single load unit – but only if the goods are sufficiently secured. Depending on the product, you might use:

• stretch wrap,
• strapping bands,
• edge protectors,
• anti-slip materials,
• slip sheets.

The type of securing required depends on the specific goods and the overall mode of transport. During transit, various forces act on the load: when a truck brakes, during handling with a forklift, or throughout a sea voyage. Pallets, packaging, and load securing should therefore not be considered in isolation.

What does pallet exchange actually mean?

Especially with Euro pallets, you often encounter the term Pallet exchangeSimply put, exchangeable load carriers can be swapped for equivalent pallets within an agreed-upon system. However, a used Euro pallet is not automatically exchangeable indefinitely.

EPAL defines criteria for exchangeability. Pallets with damage or defects that compromise their usability are no longer exchangeable and must be restored by a licensed repair facility. EPAL also distinguishes between quality classes; their application requires a corresponding agreement between the participating companies.

For shippers and carriers, this means that the condition of the pallet is also part of transport planning.

Particularly important internationally: ISPM 15

For international shipments involving wooden packaging, another issue arises: plant protection. Untreated wood can transport pests across national borders. Therefore, the international standard ISPM 15 regulates phytosanitary measures for certain raw wood packaging materials in international trade. This includes, among other things, pallets, crates, and dunnage.

The wooden packaging material in question must be treated and marked in accordance with the applicable requirements. The internationally recognized marking includes, among other things, country, manufacturer or treater, and treatment codes.

Important to note: ISPM 15 does not apply automatically to every pallet and every cross-border shipment. Among other things, wood-based materials made from processed material, such as plywood, are exempt from the standard. Furthermore, practical application depends on the requirements of the countries involved.

Especially for exports outside the EU, it is therefore advisable to check early on which requirements apply in the destination country.

Can the wrong pallet make a shipment more expensive?

Absolutely. The price of the pallet itself is only one factor. The decisive factor is the impact the choice of load carrier has on the entire transport chain. An unsuitable pallet can, for example:

• poorly utilize available cargo space,
• increase the number of required pallet spaces,
• make safe stacking more difficult,
• cause additional packaging effort,
• cause problems during handling,
• or trigger additional requirements for international shipments.

That is why efficient logistics sometimes doesn't start with choosing the mode of transport – but rather with the question of what the goods are actually sitting on.