Palletization - rules for stacking boxes

Palletization is the way goods are arranged on a pallet so that they are stable, make full use of the space, and survive transport safely. Good palletization means fewer damages, easier handling, and lower costs. Here are the most important rules.

1. Interlocking layers (cross-tying)

The simplest "column" arrangement (each box directly above the previous one) gives even counts, but it is unstable - the layers slide apart easily. More stable is interlocking the layers, that is, rotating the pattern every layer so the boxes overlap like bricks in a wall. At the cost of a slight loss of space, you gain a lot of stability.

2. Heavier on the bottom, lighter on top

The pallet's center of gravity should be as low as possible. Stack heavy, sturdy boxes on the bottom and light, fragile ones on top. This keeps the lower layers from being crushed and makes the whole pallet less prone to tipping over.

3. Choosing the box's load-bearing wall

Every box has an orientation in which it is strongest. The load-bearing wall is the one meant to carry the load from above. Position the boxes so that the "this side up" print and the strength of the cardboard are respected - otherwise the goods underneath will be crushed.

4. Don't go beyond the pallet footprint

Goods should not stick out beyond the edges of the pallet (1200 × 800 mm for EUR). Overhanging boxes are exposed to damage, hinder stacking, and are sometimes rejected by carriers. A slight margin inward is better than exceeding the footprint.

5. Stabilization: film and corner protectors

• Stretch film - wrapping binds the layers to the pallet; start from the bottom and overlap onto the pallet boards.
• Cardboard corner protectors - protect the edges and stiffen the whole load under the strapping.
• Slip sheets - level out uneven layers and distribute the pressure.

6. Double-stacking pallets

If the goods are sturdy and the transport height allows it, pallets can be double-stacked one on top of another - this doubles the number of pallet spaces in the trailer. The condition: the bottom pallet must support the weight of the top one, and the arrangement must be even and stable.

From rules to a finished layout

These rules are easy to describe but harder to apply with many box sizes at once. The Pallet3D calculator accounts for weight, the load-bearing wall, and double-stacking, and it shows the optimal, stable layout instantly in 3D - no spreadsheets and no guessing.