How to Properly Palletize and Package Freight

Bad packaging is the most expensive mistake in LTL shipping, and it’s entirely preventable. Every year, billions of dollars in freight claims are filed because products were damaged in transit. The majority of those claims trace back to inadequate packaging.

LTL freight gets handled 4-6 times between pickup and delivery. It’s loaded onto a local pickup truck, unloaded at the origin terminal, loaded onto a linehaul trailer, unloaded at the destination terminal, and loaded onto a delivery truck. Each handling is an opportunity for something to go wrong, and your packaging is the only thing protecting your products.

Choosing the right pallet

Standard GMA pallets (48” x 40”)

This is the default for LTL shipping. The Grocery Manufacturers Association (GMA) pallet is designed to fit standard truck dimensions and warehouse racking. Two pallets fit side by side in a 96-inch-wide trailer.

Use GMA pallets whenever possible. Non-standard sizes waste truck space and may incur handling surcharges.

Pallet quality matters

Not all pallets are equal. Inspect before loading:

• No cracked or broken deck boards. A broken board lets products fall through during handling.
• No missing blocks or stringers. The structural supports need to be intact.
• No protruding nails. They can snag stretch wrap, damage adjacent freight, or injure handlers.
• Dry, clean wood. Wet pallets can damage products and create mold issues.

For cross-border shipments to Canada, use heat-treated pallets marked with the ISPM-15 stamp (marked “HT”). Fumigated pallets (marked “MB” for methyl bromide) are being phased out internationally.

When to use other packaging

Crates: For oversized, fragile, or high-value items that need rigid protection on all sides. Custom crates cost $50-$200 but can prevent thousands in damage claims.

Skids: Like pallets but without bottom deck boards. Cheaper and lighter, but less stackable. Fine for heavy, durable items that won’t be stacked upon.

Gaylord boxes: Large corrugated boxes (typically 48” x 40” x 36”) on pallets. Good for loose items, small parts, or products that need enclosed protection.

Stacking and loading technique

Building a stable load

Think of palletizing like building a brick wall. The goal is interlocking stability.

Column stacking (boxes directly on top of each other) is the weakest method. Each box bears only the weight directly above it, and the stack can topple easily.

Interlocking (alternating the direction of each layer) is much stronger. Each layer locks the one below it in place. This is the preferred method for most freight.

Rules of thumb:

• Heaviest items on the bottom, lightest on top
• Keep everything within the pallet edges (no overhang)
• Fill gaps between boxes to prevent shifting
• Maintain a flat, level top surface for each layer

Weight distribution

Uneven weight distribution causes pallets to tip, fork tines to slip, and freight to shift during transit. Distribute weight as evenly as possible across the pallet surface. If your load is heavier on one side, center it on the pallet and note “uneven load” on the BOL.

Height limits

Most LTL carriers have a maximum stackable height of 48 inches per pallet (above the pallet deck). Taller loads may be marked as non-stackable, which means the carrier can’t put anything on top of your freight. This effectively doubles the truck space your shipment uses, and carriers charge for it through cubic capacity pricing.

If your load exceeds 48 inches, clearly mark it “DO NOT STACK” and expect to pay more.

Stretch wrapping

Stretch wrap is non-negotiable for LTL freight. It holds your load together, prevents shifting, and protects against dirt and moisture.

How to wrap properly

1. Anchor the wrap to the pallet base. Wrap around the bottom of the pallet (below the top deck boards) to anchor the load to the pallet itself. This is the most commonly skipped step and the most important.

2. Work from bottom to top in overlapping spirals, covering at least 50% of the previous layer with each pass.

3. Apply 3-5 complete layers around the load. More layers for heavier or more fragile freight.

4. Keep tension consistent. Too loose and the wrap won’t hold. Too tight and it can crush boxes or create pressure points.

5. Finish at the top and tear or cut the wrap cleanly.

Machine vs. hand wrapping

For occasional shippers, hand wrapping with a handheld dispenser works fine. If you’re wrapping more than 5-10 pallets per day, a semi-automatic stretch wrapper ($1,500-$5,000) pays for itself in labor savings and more consistent wrapping quality.

Banding and corner boards

Banding

Polyester or polypropylene banding adds an extra layer of security, especially for:

• Heavy loads that could overcome stretch wrap
• Tall stacks that might sway
• Loads with smooth surfaces where wrap can slip

Apply at least two bands per pallet, positioned about one-third from the top and one-third from the bottom.

Corner boards

L-shaped cardboard or plastic protectors placed on pallet corners serve two purposes: they prevent stretch wrap from cutting into carton edges, and they distribute the force of banding across a wider area. At $0.50-$2.00 each, corner boards are cheap insurance against crush damage.

Labeling

Proper labeling helps your freight arrive at the right place and get handled correctly.

Each pallet needs:

• Shipper name and address
• Consignee name and address
• PRO number or tracking number
• Piece count (“Pallet 1 of 3”)
• “This Side Up” arrows if applicable
• Weight of the pallet
• Any hazmat or handling labels required

Place labels on at least two sides of the pallet so they’re visible regardless of how the pallet is positioned on the truck. Labels on top get covered when pallets are stacked. Labels on only one side are hidden when the pallet faces the wrong way.

Why carriers charge for bad packaging

Carriers aren’t just being difficult when they enforce packaging standards. Poorly packaged freight causes real problems in their network:

Repackaging charges ($50-$150). If your freight arrives at a terminal falling apart, the carrier has to restack and rewrap it before it can go on the next truck.

Claims costs. Damaged freight means claims against the carrier, even when the root cause is poor packaging by the shipper.

Delays. Damaged freight at a terminal holds up other shipments while it’s dealt with.

Refused delivery. If freight arrives too damaged to accept, it gets sent back at your expense.

Getting packaging right the first time costs almost nothing compared to the cost of getting it wrong.

How FreightSimple helps

FreightSimple provides clear packaging requirements during the booking process and validates your shipment details to catch potential issues before pickup. When something does go wrong, our platform keeps complete documentation to streamline the claims process.

Ship with confidence.