We come to the final part of our series of four articles on pallet stacking.


Pallet boxes



In the first article, we talked about the best way to stack a pallet. If you were unable to read it, we will leave you the link here so you do not miss all this information.

In the second part of our series, we talked about the different patterns that exist for loading onto a pallet and how fundamental it is to correctly arrange the load to ensure its stability during transport, storage, and to minimize the risk of damage to the products.

The third part of our series discussed the two most important types of stacking in the industry and their differences, namely column stacking and interlocking stacking.

Now it’s time to talk about mixed pallets and the challenge they represent due to the different shapes and sizes of the boxes. Finally, we will give you some steps to follow so you can secure the load inside the pallet.

Here are some tips for stacking boxes on a mixed pallet:

  1. Separate boxes by size: Group boxes according to size so that you can place the larger ones at the base of the pallet and the smaller ones on top.
  2. Use a solid base layer: Make sure the first layer of boxes is evenly placed and aligned on all edges of the pallet. This will provide a solid base for stacking the remaining boxes.
  3. Place the heaviest boxes on the bottom: To ensure even weight distribution, place the heaviest boxes on the bottom of the pallet.
  4. Stack the boxes in layers: Once the base layer is in place, begin stacking the larger boxes in even layers. Make sure the boxes are aligned and the edges are in contact with the edges of adjacent boxes.
  5. Use fillers: If there are gaps between boxes, use fillers such as bubble wrap or cardboard to ensure that the boxes are tight and do not move during transport.
  6. Secure the load: Once all boxes are stacked, secure them with plastic wrap, strapping, or elastic bands to prevent them from moving or falling during transport.

Source: ”5 Tips for Properly Stacking a Pallet” by Legacy Supply Chain Services: https://legacyscs.com/5-tips-for-properly-stacking-a-pallet/


To conclude and make our pallet loading series complete, it is important to mention some tips to effectively secure the load on a pallet to prevent it from tipping or being damaged during transport. To do so, follow these recommendations:

1.- Selection of the right pallet:

Use high-quality pallets that are strong enough to support the weight and nature of the load. Pallets should be in good condition, free of cracks and splinters, and preferably of standard dimensions for ease of handling and stacking.

2.- Uniform load distribution:

Distribute the load evenly on the pallet to maintain proper balance. Place heavier items in the center of the pallet and lighter items at the ends. This will help prevent the pallet from becoming unbalanced during transport.

3.- Use adequate packaging material:

The packaging material plays a crucial role in securing the load on a pallet. Use a tough, high-quality plastic film to wrap the load. The film must be thick enough to withstand the stresses of transport and protect the products from dirt, dust, and moisture.

In addition to plastic film, consider the use of straps or elastic bands to further reinforce load securing. Securing with plastic or steel straps that can be tightened around the pallet will help keep the load compact and prevent it from slipping. Elastic bands are also a good option as they conform to the load and help keep it stable.

It is important to apply the proper amount of tension when wrapping the load. If too much tension is applied, it can damage the products, especially fragile products. If too little tension is applied, the cargo may shift during transport. Find a balance by applying just enough tension to maintain stability without compromising the integrity of the products.

4.- Add additional reinforcements:

In some cases, especially when handling heavy or fragile loads, it may be necessary to add additional reinforcement to the pallet. Cardboard or wood corner pieces can be placed at the corners of the pallet to provide additional protection and prevent damage from impact or shock. These corner pieces provide additional support and help maintain the structural integrity of the pallet.

In addition to corner pads, consider using foam or cardboard pads between items in the load. These pads act as shock absorbers and prevent products from rubbing and damaging each other during transport. Strategically place the pads in areas where friction or impact is expected to provide an additional layer of protection.

5.- Properly secure the pallet:

Once the load is secured on the pallet, it is critical to properly secure the pallet to the transport platform. Use strong straps or tie-downs to securely fasten the pallet to the surface of the truck, trailer, or sea container.

Make sure the straps or lashings are strong enough to withstand the load and forces during transport. Adjust the straps so that they are firmly taut, preventing unwanted pallet movement during transit. If necessary, use load blocks to prevent lateral movement of the pallet.

6.- Label the load:

Proper labeling of cargo is essential to ensure proper handling and efficient transportation. Place labels on the pallet with relevant information, such as load content, weight, handling instructions, and any other important information for logistics operators.

Labels help to quickly identify cargo, ensure it is handled correctly, and facilitate the unloading process at the destination. Use clear and legible labels.

EasyCargo is an online software that, thanks to its simple design, can perform an unlimited number of load planning calculations. This will help you have several options when it comes to loading for transport as well as optimizing the shipment. Learn more about how you can benefit from this software by trying it for free here.

In summary, freight optimization is a critical factor in modern logistics and EasyCargo stands out as a must-have tool for maximizing the use of your cargo space as well as minimizing unnecessary costs. We hope this article has given you a clearer picture of how proper freight planning can transform your logistic operations.

Martina Krupičková | 7. marras 2023