A Pallet Stacking Guide

When stacking and loading/unloading pallets, load stability is important; stacking pallets incorrectly can make the entire load topple over, causing significant product damage and loss. During handling and transportation, loosely wrapped pallets with an uneven weight distribution can cause products to shift or even fall. As such, we ensure that the pallet orders we send are appropriately balanced and tightly packaged for the safety and convenience of our customers. When unloading the pallets, it is important not to compromise the integrity of the load’s balance. So, in this short article, we will explain a few common pallet stacking variations used by Container and Packaging and provide you with best practice advice for how to find what you’re looking for on a pallet and safely unload it.  

How are Pallets Stacked?  

When stacking various packaging products on a pallet for shipping, there is no “one size fits all” method. The way that the pallet is stacked will depend on what is being stacked along with the sizes, weights, and fragility of the products and boxes. The Container way will let you know what to expect! 

Pallets Stacked by our Warehouses

Pallets stacked in our warehouses will either be stacked in a columnar-aligned pattern (cases placed one on top of the other creating a column) or a interlocked stacking pattern (Each layer is stacked opposite the one below), and will adhere to the following guidelines: 

• Heavy items on the bottom (This is to provide the most support when moving the pallet) 
• Stack pallets evenly (without too much hanging over the edges) 
• Include boxes that are partial case-fulles with a sticker to identify the boxes as “partials” 
• Abide by Height/weight Limitations 
• Never use damaged pallets 
• Plastic wrapping for shipping 
• Labels and pallet tags 

Below are some examples of pallets that have been stacked in our warehouses:  

COLUMN STYLE STACKING (columnar-aligned pattern) 

Column stacking is when the same footprint is maintained all the way up the pallet and cartons are stacked directly on top of each other. This approach allows each box to support the others along its stronger edges and corners, reducing the risk of individual box damage. Most commonly used when your boxes are directly proportionate to the pallet size (48”x40”) 

INTERLOCKING STYLE STACKING

Interlocking pallets provide stability when in transit and when stacking pallets atop one another (commonly seen in warehousing) 

Mixed Pallet example 

Heavy Cases on bottom, partials indicated with sticker (green), interlocking glass.

Here is the same stack from a different angle after being WRAPPED, 

Here is the same stack from a birds-eye angle to show the partial case sticker and pallet tag (QR code will allow customers to scan and print packing slip) 

Pre-stacked pallets from the manufacturer 

When ordering full pallets or multiple full pallets of the same item, the pallets might be assembled differently than shown above. In some cases, the pallet will be stacked the same way that we received it from the manufacturer.  The items pictured below come to us directly from the manufacturers, packaged either using a column stacking method (described in the section above) or a layer packed method (Cardboard layers, stacked and shrink wrapped all together). Keeping the pallets stacked the same way they came from the manufacturer allows us to fit the most containers per pallet instead of using boxes and limiting the number of containers to our box sizes. Layer packed pallets also tend to be highly stable because of their lighter weight. As an added benefit to our warehouse team, using the manufacturer’s pallet stacks lessens packaging/processing time and as they do not usually require extra steps to complete the order. This is more beneficial to you as your order can be shipped that much faster.  

Below are some examples of items that are layer packed and are best to purchase and ship on a pallet the way they arrived in layers from the manufacturer.  

Some large plastic jugs are layer-packed. 

Sometimes large plastic jars, bottles, and cannisters are layer-packed. 

Pallets of tubs and jugs are also commonly layer-packed. 

Opening a Pallet

When unloading and receiving your pallet order, here are the best practices to use:  

Unloading  

• Always check the BOL (Bill of Lading) and verify case count on the pallet versus the paperwork. At this time, it is important to note if all cases are account for or any damage that you may see. Please mark this on the driver BOL when signing and please take pictures. (This is important! If damage is not reported on the BOL at the time of delivery, it is very hard to investigate and assess for the proper solution) 

• Your packing slip is included though it may not “jump off the pallet” to you! Please note on the Pallet tag, you will find a “QR Code”. This code can be scanned by any device and pull up your packing slip for easy viewing and printing 

• If you had any partial cases on your order, you would find these in a box with a GREEN STICKER “Partial Case” and a Packing Slip stating your partial items and quantities. 

• You will also notice that the pallets are stacked with the item label facing outward for easy reading 

Breaking down/opening your pallet 

• Always best to start from the top! If your pallet is mixed and you need items from the bottom, cut the pallet wrap off the pallet and down stack for put away and use  

• When using only the top of the pallet (by layer), you can cut the pallet wrap off to just expose the layer you’re using, this way the bottom layers remain their most stable 

• Our warehouse team members usually have the help of another team member to ensure the stability of the layer as they unload each layer. We recommend this practice for you as well – it is always easiest and safest to unload a pallet with a partner.