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Mastering pallet packing: mistakes to avoid

August 19, 2021

Packing pallets correctly can be a vital step in the warehousing of your goods. If you have created a brilliant product, or you ship in essential parts for assembly, it would be disastrous to have them damaged due to a packing issue that could be avoided. To ensure the structure and strength of your shipments, you should follow best practices. As a leading pallet supplier in Sydney, here are our top mistakes to avoid when optimising your pallet packing.

Incorrect Packing

Packing items on pallets requires planning, attention to detail, and following certain procedures. Workers should stay mindful when they pack products, doing it in the safest way possible. There are many different ways to stack your products, but care should be taken to avoid the common mistake of overhang. Pallets should also be fitted to the shipment they are holding. Using the wrong sized pallet will result in disorganisation and potentially damaged products. Furthermore, labelling your shipments correctly is essential. If mistakes are made on labelling information, fragile items can be ignored, or unsafe chemicals could be stored incorrectly. Make sure all necessary information is correct when labelling your shipments.


Improper Stacking 

Stacking pallets can be an art form when it is done well. Pallets should be stacked in orderly rows, starting with layers from ground level. When storing pallets, you should stack them no higher than 4.5m to ensure everyone’s safety. In general, the height of your stack should not exceed the length, but this can depend on the type of product you are stacking, and whether or not you plan on double stacking. If the pallet is not stacked properly, it can cause the shipment to arrive damaged, or even cause damage to other pallets. It is crucial that you avoid improper or sloppy packing.


Using The Wrong Pallet

Choosing the correct pallet for your shipments will ensure that you are able to pack your pallets correctly. Make sure it is the right size for your products so there is no overhang.

Consider which material is best for your pallet needs. While wooden pallets are the standard, pallets with other materials have also entered the market. Would plastic be sturdy enough to support your load or is wooden preferred? Furthermore, some treated woods cannot be sent overseas, which should be considered at the beginning of your pallet purchase decision process. You do not want to have to repack your shipment, losing time and money.


Using Damaged Pallets

Quality wooden pallets should be kept in good working order to optimise functionality and ensure the safety of those working in logistics and transport. Signs to look out for if pallets are damaged include rotting woods, cracks, oxidation and pallets that do not lie flat.

You can also look at repairing your pallets to minimise costs to your business.



Neglecting to properly prepare and pack a pallet can result in loss of goods, damaged goods, and complications with shipping. Prevent that ahead of time and master the pallet packing process. Talk to Cooperage Pallets today about finding the best pallet solution for your business.