Everything You Need To Know To Find The Best palletization online

How does it work?

Enter in information related to your unit and pallet size, and desired configuration. Our pallet builder will generate a 3D visual rendering of your full pallet load and provide a comprehensive list of helpful measurements and specifications.

Contact us to discuss your requirements of palletization online. Our experienced sales team can help you identify the options that best suit your needs.

Step 1 – Unit information

Type in the width, length, height and weight of your units, whether boxes or bags.

Step 2 – Pallet data

Select your preferred pallet size from the predefined list. Create a custom dimension if your pallet size is not listed, or if pallet height is different than the default of 6 in or 152 mm.

Here are the most common pallet sizes:

48” x 40”

• Most standard pallet type across North America
• Safe working load up to 4,600 kg

1200 mm x 800 mm

• Standard across European countries
• Safe working load up to 1,500 kg

1200 mm x 1000 mm

Commonly used in Europe for larger loads

• 40” x 24” (North America)
• 800 mm x 600 mm (Europe)

Used for smaller loads that won’t fill a full pallet but still need to be shipped

Step 3 – Layer configuration

Here, you have the option to let the calculator determine the optimal number of units per layer or to specify your desired quantity.

Then, select the appropriate layer configuration for your project from a range of options, as well as choosing whether the units will be aligned with the pallet or overhang.

Step 4 – Layer alignment

Specify your total load height (number of layers). Then select the desired layer alignment to improve the stability of your pallet load.

Alignment can be:

• H-mirrored: units are mirrored horizontally along the center of the pallet
• V-mirrored: units are mirrored vertically along the center of the pallet
• Rotated: units are rotated, typically by 90 or 180 degrees
• Parallel: units are aligned in the same direction on the pallet, either horizontally or vertically

Step 5 – Results

At this final step, you receive a full list of specifications for your pallet including:

• Total dimensions
• Total weight
• Total height
• Units per layer
• Total number of units
• Surface usage

These numbers are also downloadable into a file for future reference.

How to Choose the Best Pallet for Your Business

Choose the correct pallet type to avoid repalletization at your 3PL warehouse, which comes at an added cost, or worse, get penalized by Amazon for having the wrong pallet type.

Here are the top six things you should consider before investing in pallets.

Amazon Pallet Requirements

Before shipping your inventory to Amazon, make sure that your pallets meet the following requirements:

Pallet Type

Ship your products on 40 x 48-inch, 4-way access wooden pallets.

Grocery Manufacturers Association (GMA) Pallet Specifications

The food industry, including Amazon, follows the pallet guidelines set by the Grocery Manufacturers Association (GMA)–recently rebranded as the Consumer Brands Association. These guidelines aim to ensure fast and smooth movement of products throughout the US.

Based on GMA’s guidelines, pallets are divided into two main groups – Grade A and Grade B – to identify the differences between the most like-new pallets and those with minor cracks or imperfections. In some cases, these grades are also referred to as #1 and #2. These grades are based on the pallet’s general appearance (Grade B pallets normally have a more worn appearance than Grade A pallets), compliance with GMA requirements, structural integrity, and how much repair is needed to make the pallet usable.

Within Grades A and B, there are several subcategories to make a clearer distinction between higher quality and lower quality pallets. It’s best to familiarize yourself with these classifications to better understand Amazon’s pallet requirements, so you can request the correct pallets from your suppliers or freight forwarders.

Premium Grade A or #1A
Often marketed as good as new, premium Grade A pallets have a bright wooden color and have no visible signs of extensive repair. Not only are they perfect for shipping and storing food and grocery items, but also for in-store visual merchandising (improving your product’s visual presentation to better highlight their features and benefits). Some grocery stores use premium pallets as part of their retail display to attract the attention of shoppers.

Melon Grade or #1B
These pallets are almost similar to #1A, in that they normally don’t have any obvious signs of repair. The only difference is that Melon Grades often have some minor damage or discoloration, making them slightly inferior to their premium Grade A counterparts.

Regular Grade A or 1R
Sometimes referred to as Regular Grade, these pallets have been refurbished to achieve like-new condition–for example, replacing damaged or broken deckboards with good-quality recycled boards to match the pallet being repaired. This makes 1R pallets more affordable than Premium A and Melon grades, although they generally have a more worn appearance.

Premium Grade B or #2
These pallets may have had some type of repair done to one of the stringers. For example, adding a sturdy piece of wood to the broken or cracked stringer for extra support. However, these repairs should make the premium B grades durable and stable enough to carry loads without trouble.

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Standard Grade B
This grade is the lowest standard grade offered by many manufacturers. This also means B grades are the cheapest, albeit some parts of these pallets may either be cracked or missing, thus they will likely need to undergo extensive repair versus higher grades that are still fairly in good shape save for a few discolorations or minor repairs.

To stay compliant with Amazon’s pallet requirements, be sure to follow the guidelines below:

Ship units on GMA Standard B Grade or higher pallets that have:

• 6 or 7 top deckboards. The amount of top deckboards will largely depend on the width of the boards.
• 4 access points
• At least 4 bottom deckboards
• 3 stringers
• No obvious signs of repair done to the stringers (e.g., reinforcing the stringers with a wooden block or a metal plate)

Ship grocery items on GMA 1A Grade pallets that have:

• 7 top deckboards
• 5 bottom deckboards
• 4 access points
• 3 stringers
• No block repairs done to the stringers

Ship health and personal products on GMA 1A and 1B Grade pallets that have:

• 6 or 7 top deckboards. Again, the amount of top boards you can attach to your pallet depends on board thickness.
• At least 4 bottom deckboards
• 4 access points
• 3 stringers
• Only one stringer may have some type of repair. For example, adding a block or plug (a piece of a stringer nailed next to an existing damaged stringer) to improve the overall structural integrity of the pallet.

Lastly, only use pallets in good condition. Damaged or broken pallets may be rejected by Amazon at your expense.

Pallet Height

AMZ maximum allowable height for pallets depend mainly on whether you’re using a:

Non-Stackable Pallet

Also known as single pallet, a non-stackable pallet is a pallet that cannot be stacked due to the odd shape of the unit it’s holding or simply because it has a “Do Not Stack” label affixed to it. A single pallet freight shipment must not exceed 72 inches in order to be approved by Amazon.

Keep in mind that you will also have to take the height of the pallet itself into these limitations. A standard 40 x 48 inches pallet normally has a height of 6 inches. That means you only have 66 inches (72 – 6) of carton height to stack if using a non-stackable pallet.

Note that some carriers like FedEx apply a surcharge to non-stackable freight shipments. This is generally due to the fact that a non-stackable 72” pallet takes up less vertical space in the truck than a pair of stackables does. Carriers, therefore, may want to charge you for the unused space. Check with your carrier for more details.

Stackable Pallet

Stackable pallet means stacking two or more pallets on top of each other. You can ship your units on a double-stacked pallet into Amazon, but the total stacking height, including the pallets, must not be higher than 100 inches (50 inches per pallet stack). So, for each stackable pallet, you only have 44 inches of carton stack height due to the 6” of pallet materials. Using a double-stacked pallet is space-efficient as it allows you to maximize vertical trailer space for standard semi-trailer height. So, it can be a good option if you regularly send in hundreds of boxes per Less than Truckload (LTL) or Full Truckload (FTL) delivery.

Pro tip: Talk with your 3PL to find out what they prefer (stackable or non-stackable). It’s important to consider the height of your truck when palletizing, as you may be able to fit more units per truckload with a pair of stackable pallets than a single pallet. But again, discuss with your 3PL for the best advice. Additionally, read Amazon’s Seller Requirements for LTL, FTL, and FCL Deliveries for more information.

Floor Loading

If you’re thinking about floor loading your shipments to maximize space and reduce costs (no need to buy pallets), bear in mind that floor loading does not work for all shipments.

Heavy and bulky items, such as carpets, large appliances, furniture, cast iron pipes, or tires may arrive in floor-loaded containers. But fragile goods shouldn’t be floor loaded to reduce risk of damage during transport.

In addition, Amazon often rejects floor-loaded shipments that require extensive warehouse labor or handling, such as boxes that weigh more than 50lbs each. Or, those shipped in a trailer with a corrugated or uneven floor.

And since floor-loaded shipments require extra work, it takes longer for warehouse associates to process your inventory, which may delay its availability for sale on Amazon. That’s why Amazon recommends palletizing your inventory as much as possible to avoid such costly delays.

But if palletizing isn’t really an option for you right now, make sure to notify your carrier when you know that your shipment will be floor loaded. They will then review your request and let you know whether your floor-loaded shipment is accepted. If accepted, they may impose extra charges that would vary depending on the extra handling and time required to process your cargo.

When preparing your floor-loaded shipment, work closely with your carrier to make sure your shipment meets Amazon’s Floor Loading Policy. This will help you to avoid unnecessary charges or shipment rejections and to ensure safe loading/unloading procedures and timely delivery and check-in.

Pallet Weight

The total weight of the pallet – both stackable and non-stackable – must not go over 1,500lbs (680kgs). To ensure efficient loading/unloading, receipt, and storage of your products in FBA, each carton on the pallet should not weigh more than Amazon’s standard box weight limit of 50lbs (23kgs), unless it contains a single large or oversize unit that weighs more than 50lbs.

Pallet’s Compatibility with Your 3PL’s Current Handling Equipment

Pallets are usually categorized as two-way and four-way, and each has effects on how they can be lifted or handled. For example, forklifts can’t enter a two-way pallet through the sides of the stringers (i.e., it can only be lifted from the front and back), whereas four-way entry pallets can be accessed from any side. This is something very crucial for some warehouses. In fact, certain warehouses like Amazon only utilize four-way access pallets mainly because they’re more efficient and convenient than pallets with only two entry points.

So, make sure that your pallets work with your 3PL’s existing handling equipment before making that investment. Again, talk to your 3PL if you have any concerns.

Load Capacity

Load capacity refers to the maximum weight a pallet can hold. Make sure that your pallets can handle the load you expect them to carry.

Remember that Amazon has set a total weight limit of 1,500lbs per pallet. So, if your cargo weight is going to be that heavy, use pallets that are made out of sturdy and high-quality materials.

For instance, hardwood (oak and pine) is ideal for shipping heavy items. Conversely, lightweight wooden pallets (plywood) or those that have been badly damaged due to extensive use might not be durable enough to hold your inventory once fully loaded.

Durability

Durability refers to the ability of the pallet to withstand the impact of rough handling as it goes through various stages of shipping (e.g., moved along by forklift or conveyor). When testing for durability, look for signs of wear and tear on the pallet, such as the impact of forklift blades (aka fork tines) on the deckboards. If the damage is extensive, you may need to replace them with new ones or higher-grade pallets.

If the pallet is for single use only, then durability may not be a crucial factor in your decision. Volume or cargo weight is also another thing to consider when making a selection. If you’re planning to ship high volumes or heavy objects across long distances, you will need to use premium pallets to get the best value for your hard-earned money.

Pallet Stiffness

Pallet stiffness can be defined as the measure of how much a pallet bends out of shape under load over time. If the pallet collapses, boxes will bulge at the sides due to crushing pressure, resulting in load instability and damage to your products.

It’s crucial that the pallets will hold their shape when fully loaded. The heavier your cargo is, the higher stiffness rating you’ll need to transport the units within the boxes safely.

When it comes to wooden pallet stiffness, thicker deck boards are always better. While thicker pallets are more expensive than thinner pallets, the benefits simply outweigh the risks, including the cost of inventory shrinkage due to damage.

Pro tip: Investing in stiffer pallets is just one way to ensure maximum protection of your cargo. Using sturdy boxes is just as important. The compression strength of boxes (ability to withstand pressure when placed between upper and lower boxes) can be increased by adjusting the flute size and cardboard grade. Check out How to Choose the Right Master Carton Size and Type for more information.

Budget

How much are you willing to shell out for pallets? Which pallet type will provide the best value?

Price may be a huge factor in your selection process, especially given the fact that, as of November 2021, it would now cost you around $21 to buy a new wooden pallet in the US. Before the pandemic, pallets only cost $12 a piece. A $9 increase over the last 12 months (2020 to 2021) is huge for many sellers, and therefore, buying pallets at today’s price understandably requires some serious consideration.

However, you still can’t go wrong with high-quality pallets as they are less likely to break down at your warehouse, while in transit, or at Amazon. Anything less could lead to inventory breakage and additional fees for new pallets and repalletizing, costing you more money in the end.

Related: Inventory and Logistics to Stay Profitable in 2022

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