Pallet stability is the backbone of a safe and efficient operation. No matter if you’re shipping goods across the country or stacking them high for storage, how you build a pallet directly impacts the safety of your team and the integrity of your products. As such, it's a fundamental part of logistics that, if done properly, saves time, money and headaches.
To help you get things done right from the start, here’s a quick guide to stacking pallets like a pro, ensuring your loads stay secure from the warehouse floor to the delivery bay.
The pallet itself is your base. Always choose one that's the right size and strength for your load. A pallet that's too small or weak is a recipe for disaster, risking overhangs and buckling. While standard UK (1200x1000mm) and Euro (1200x800mm) pallets are common, the key is to ensure the one you use is in good condition and free from damage. Find the right pallet for your operational needs by checking out our range.
A classic mistake is stacking a load in a pyramid shape, with items tapering off toward the top. This approach, while seemingly stable, creates a weak point. Instead, build your load in solid columns, with each box directly above the one below it. This distributes weight evenly and significantly reduces the risk of toppling.
Avoid overhangs at all costs. An overhanging box can lead to uneven pressure, crushing, and shifting during transit. Keep all boxes aligned with the edges of the pallet and stack them as tightly as possible. A flat, square top layer is also essential for safely stacking another pallet on top.
This might seem obvious, but it's a golden rule that can't be overstated. Putting heavier items at the bottom creates a low centre of gravity, which is crucial for stability. It also protects the lighter items from getting crushed.
Securing a pallet is just as much about the materials you use as it is about techniques. A few key items can make a huge difference:
Products like grip® stretch film, shrink pallet covers, and Edge PRO-TEC™ edge protection are great examples of products that can prevent shifting without slowing down your process.
Any empty space between products allows for unwanted movement. Use void fillers or adjust your stacking pattern to eliminate gaps. For irregularly shaped items, consider custom packaging to maintain a solid, even footprint.
Simply wrapping a pallet isn’t enough; you need the right technique. Whether you're using a machine or wrapping by hand, start from the base and secure the film to the pallet itself. Overlap each layer by at least 30–50% with consistent, tight tension to ensure a secure hold.
Every pallet has a limit. Exceeding it can lead to collapses or make the load unmanageable, risking damage to products, equipment, and racking systems. Always check manufacturer guidelines before you start stacking.
When a load’s stability is in question, put it to the test. Use tilt tests or shake tests to see how it holds up under stress. If you need more support, our Pallet Stabilisation Consultation Service can help you assess and improve your process. Contact us to find out how we can assist.
Even the best materials can't fix poor practice. Ensure your team is properly trained on safe stacking techniques, equipment usage, and common risks. Standardising this knowledge across your operation is key to consistent, safe pallet building every time. Pallet stability is clearly about far more than just avoiding damage. It’s an essential component of safe shipping and transport that protects your entire supply chain, your team, and your bottom line.
We offer a wide range of packaging solutions designed to fit your unique needs. Whether you’re looking for robust equipment, sustainable packaging, or custom transit solutions, we have the tools to help.
Ready to improve your pallet stability? Reach out to us to learn more about how we can help you create a safer, more efficient process. You can email us at sales@allpack.uk.com, send us a message, or give us a call at 01543 396700 to discuss your requirements.