While “standard” wooden pallet sizes appear uniform across warehouses, “standard” does not necessarily equal “universal.” In fact, each industry has its own preferred pallet dimensions, and what fits perfectly in one operation may cause major disruptions in another.
Because getting pallet sizes correct can greatly affect your operation, you want to avoid incorrect sizing. Incorrect sizes can result in wasted space, compatibility issues with your material handling equipment, and frustration anytime you need to move or store goods.
Local Standard Size (and why it exists)
The most commonly used pallet size in most areas is 1165mm x 1165mm, approximately 46 inches square for those still thinking in terms of imperial measurement. This pallet size was developed to allow for efficient use of shipping containers and warehouse racking systems.
In addition to maximizing the number of pallets placed end-to-end across the width of a shipping container or truck bed, the square configuration allows for easy rotation of pallets without loss of space efficiency.
However, this “local standard” is not universally accepted, as many businesses use non-standard dimensions due to specific business needs, or international shipping that follows a non-local pallet dimensioning convention.
Common alternative pallet sizes
There are several other pallet sizes utilized for specific applications, beyond the primary standards. For example, half pallets (typically 1165mm x 580mm) are ideal for lighter loads or for products that do not occupy the entire surface of a standard pallet.
Quarter pallets exist as well, although they are relatively rare. These are useful for small batch movements, such as retail display applications.
Many industries develop their own pallet sizes based upon the type of products being shipped. Beer and soda manufacturers typically utilize pallets sized to accommodate their bottles or cans. Food service retailers may utilize pallet sizes that correspond to standard refrigerated unit or delivery vehicle dimensions.
When Custom Pallet Sizes Make Sense
Although custom pallet sizes typically cost more and introduce additional logistical complexities, sometimes the advantages of custom pallet sizes far outweigh the disadvantages. For instance, if your products are irregular shapes and sizes, a custom pallet design may be necessary to support those products. Additionally, if your products are unusually heavy, custom Wooden Pallets in Melbourne may be needed to ensure the structural integrity of the pallet and prevent collapse during shipment.
Another situation where custom pallet designs make sense is when the quantity of product you ship always falls within a specific range, and therefore a pallet design that accommodates those exact volumes would be advantageous.
The major disadvantage of custom pallet designs is limited flexibility. Because custom pallet designs are tailored to meet the specific needs of your operation, they may not fit the needs of other businesses as easily. As a result, you may find yourself relying solely on a specific supplier for replacement pallets, which can negatively impact lead times and availability.
Pallets must be compatible with your equipment
This is where many businesses encounter unforeseen problems. Pallets must be compatible with your forklifts, pallet jack, racking systems, and vehicle dimensions. If your pallets are incompatible with these pieces of equipment, you will continually struggle to move and/or store your goods.
Racking systems are built for specific pallet sizes. If your pallets are larger than the racking bays, they will not fit properly within the bays. Conversely, if your pallets are smaller than the bays, they will either not rest stably within the bays, or they will occupy excessive amounts of space within the bays. The gaps between the pallets and the racking system are important considerations for both safety and productivity.
Most forklifts and pallet jacks have adjustable fork spacing; however, there is a point at which the forks cannot be adjusted further to accommodate extremely narrow or wide pallets, and special equipment may be required.
Additionally, the dimensions of vehicles used for delivery and/or shipping will determine how effectively pallets can be loaded onto those vehicles. Each piece of equipment has its own dimensions for optimal use of pallet space. Some pallets will load and unload from delivery trucks, shipping containers, and warehouse loading docks more efficiently than others.
Space Efficiency – Both in Storage and Transport
Businesses often focus on pallet sizing because of the implications it has on space efficiency – both in storage and in transportation. Wasted space in your warehouse, or in the vehicles transporting your goods, results in unnecessary expenses associated with renting warehouse space, consuming fuel while transporting your goods, and the capacity of goods you can move in a single trip.
The mathematics behind pallet sizing become apparent once you consider the effects of a few centimeters in the dimensions of the pallet. A few centimeters in the pallet dimensions can result in one fewer pallet being able to fit in a row in your warehouse, or one fewer pallet being able to fit in a shipping container. Once you multiply those differences by thousands of pallets, the total impact becomes evident.
However, simply maximizing pallet density is not the only way to achieve space efficiency. Ease of worker access and movement, stability of the stack, and potential safety issues related to the configuration of the pallets also contribute to overall space efficiency.
At times, a slightly lower pallet density can result in higher overall space efficiency through increased pick speed, reduced handling time, and reduced damage to your products.
Height Factors – Frequently Overlooked
Everybody concentrates on the length and width of the pallets, but height is a factor that is frequently overlooked. Standard pallets are generally around 150mm thick, but this thickness can vary depending on the construction method of the pallet and the weight-bearing capability of the pallet.
Higher pallets provide greater clearance for forklifts to operate under, but limit the amount of stacking you can perform prior to reaching the ceiling or racking height limitations. Lower pallets enable greater vertical stacking capabilities, but may not function correctly with all of your material handling equipment.
Also, the distance between the top of the deck board (the top surface) of the pallet and the bottom frame of the pallet varies. The gap between the deck boards and the bottom frame impacts how securely your goods sit on the pallet and how effective strapping or wrap is in securing your loads during shipment.
Selecting the Proper Pallet for Your Business
To begin selecting the proper pallet size for your operation, measure your storage space and equipment. Knowing the size of your racking bays, the capacity of your vehicles, and what your forklifts can comfortably lift provides the basis for determining the acceptable pallet size.
Determine what you are shipping or storing. Heavy or dense products typically require sturdy pallets that may be larger or smaller than the typical pallet size for lighter or bulkier products.
Consider your supply chain. If you are consistently interacting with other businesses, utilizing a pallet size that is compatible with their systems minimizes friction and transfer costs.
Lastly, consider cost. Standard pallet sizes are typically cheaper and easier to obtain than custom pallet sizes that solve a specific problem but cost more and provide less flexibility.
Unless there is a compelling reason to choose a different pallet size, for most businesses, standard pallet sizes provide the best combination of cost, availability, and compatibility with local logistics systems.
