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Stacking goods on the pallet


When planning the distribution of goods on a pallet, several factors need to be taken into account. The key is to combine maximum use of available space with cargo security. Goods are exposed to damage at each stage of shipping – from completing, through transport and unloading. The choice of an appropriate pallet, collective packages and proper arrangement of loads on the pallet can minimize this risk.

Warehouse workers and order pickers are responsible for distributing the goods on the pallet. However, it is the manufacturer’s task to select the right packaging for the goods, as well as to choose a pallet adapted to the type of load.

Packaging dimensions have a major impact on the optimal distribution of goods on the pallet.

  • Cardboard boxes being an aliquot of the dimensions of a standard europallet may come in useful. This type of package makes planning of proper arrangement of loads on the pallet much easier.
  • Irregular shape of packages may turn out to be quite a challenge. If you stack tubes on the pallet, a good idea is to put a wooden or cardboard plate at their ends so that they can be easily secured with belts.
  • In case of goods with irregular shape, they need to be placed in a special box or cardboard and a filler should be applied.
  • The filler or anti-bumping materials ought to be also used in packages that are filled with goods incompletely. Leaving empty space in collective packages may weaken the construction and result in damage of goods.

The type of pallets to be used is usually decided on by the manufacturer. However, it is recommended to examine their technical condition before stacking the goods. It is checked if the pallet is broken or cracked, in case of wooden pallets – if wood is rotting. A europallet, with its dimensions 120x80x14,4cm, is one of the most popular pallets. It weighs around 25 kg and its capacity ranges from 1000 to 1500 kg depending on the load arrangement. If the europallet is used solely for the purpose of storing goods without moving them, then its carrying capacity may reach even 4000 kg. The maximum height of a load on the pallet is 220 cm.

How do I stack goods on a pallet?

Above all, the weight should be distributed evenly, taking into account the load capacity of the pallet. When stacking goods on the pallet, the weight should be laid out evenly taking into account the load capacity of the pallet. Heavier packages are put at the bottom. The construction will be more stable if the center of gravity of the load will be in the same place as the center of gravity of the pallet. Loads can be stacked on the pallet or intertwine with one another. During planning the ratio of height and width and the weight of the pallet with the load should be taken into consideration. Packages ought to be stacked on top of each other so that they do not protrude beyond the edge of the pallet, which will facilitate securing it with foil, increase safety of goods during transport and also help in planning the arrangement of pallets on the loading space. Pallets do not have side walls, thus, goods must be arranged in such a way that they do not slip or the pallet with the load does not fall over.


Goodloading – pallet loading calculator

Goodloading can be used to plan the distribution of goods on a pallet. It is a web-based App for planning loading in any cargo space. It is used not only by carriers and shippers, but also by manufacturers and warehouse workers. The App is equipped with multiple algorithms that distribute the goods in such a way as to make maximum use of the available space. This saves the planner an amount of space on the pallet and, as a consequence, in the cargo space or warehouse.

How does the palletisation feature work in Goodloading? Once logged into the App, the user selects the dimensions of the pallets and their quantity. The next step is to add the goods to be stacked on the pallet. Goods can be added in bulk from a spreadsheet or manually by entering their dimensions and weight one by one. The App will automatically distribute the added goods into pallets taking into account the parameters set by the user. The prepared design can be seen in the 3D visualisation, with the option of moving goods manually. The ready-to-use pallet loading design can be downloaded as a PDF file or made available as an editable or viewable link.

An additional feature in the App is the ability to plan the stacking of such prepared pallets into the loading area of a semi-trailer or container.

For safety reasons, the correct distribution of goods on the pallet is extremely important.

Improper stacking of goods on the pallet without considering load or checking the technical condition of the pallet decreases safety of the load. During transport cracked pallets may break down or collapse under the weight of goods. Damage may also take place in a warehouse or while completing an order. In this process it is also important to arrange goods according to their weight and dimensions. The appropriate collective package should also be taken into consideration.

Safety of goods during transport is influenced by suitable driving style (e.g. avoiding sudden braking or acceleration) and proper loading which should be carried out by a person entitled to operate a forklift. In terms of security of not only goods, but also the driver and other road users, appropriate stacking of pallets on the semi-trailer and correct load securing play an important role here.

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