Guides
How to choose a pallet size
Reviewed
Choose a pallet size by starting from the product's footprint so the load neither overhangs the deck nor leaves large empty margins, then checking that the size fits your trailers or containers, racks, handling equipment and your customers' requirements. In the US the default is 48 x 40 in (1219 x 1016 mm); in Europe it is 1200 x 800 mm or 1200 x 1000 mm.
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The right pallet size is the one that fits the product and every piece of equipment it meets. Most of the time that points to a standard size, because standard sizes are what trailers, racks, pools and customers are built around. When it doesn't, a custom size is normal and costs little extra at volume.
Step 1: Start from the product footprint
Lay out the cases, bags or drums in a pattern and measure the result. The pallet should match that footprint closely.
- Overhang (load extending past the deck edge) is the one to avoid. Cartons that hang over the edge lose support at their corners and walls, which is where they carry most of their stacking strength, and overhanging product is exposed to forklift and rack damage. See load overhang.
- Underhang (deck showing around the load) wastes cube and can let the load shift, but it is usually the safer error.
If you are still designing the cases, it can pay to size them to a standard pallet rather than the reverse. Unit load design covers the system view.
Step 2: Check the vehicle
For US domestic freight the 53 ft trailer is the reference. Its inside width is roughly 98 to 101 in, so:
- Loaded straight (48 in side running along the trailer), two 48 x 40 pallets side by side use 80 in of width, and each row takes 48 in of length.
- Turned (48 in side across the trailer), two pallets use 96 in of width, but each row takes only 40 in of length, so more rows fit.
That is why a standard 53 ft trailer takes 26 pallets loaded straight or up to 30 turned. The pallets per truckload guide shows the calculation. ISO shipping containers are narrower inside (about 92 in, 2.35 m), so two 48 in pallets will not fit side by side, and container loads need their own layout.
Step 3: Check the racks and handling equipment
- Racks: the pallet's orientation in the rack decides which parts span the beams. With the stringers running front to back, the stringers bridge the front and rear beams; turned the other way, only the deck does. Rack depth and beam spacing are set for one footprint. See racking pallets.
- Forklifts and pallet jacks: fork length and spread must suit the pallet's entry face. See pallet jack compatibility.
- Automation: conveyors, stretch wrappers and AS/RS are often built for one footprint and a tight flatness tolerance.
Step 4: Check customer and pool requirements
Many receivers specify a size. The GMA 48 x 40 footprint is the North American grocery standard, and the major pallet pools in North America rent 48 x 40 block pallets. Some retailers also specify construction and documentation; always confirm with the customer's current vendor guide. See GMA and pooled pallets.
Step 5: Consider export
For export, match the destination's handling system where you can, and use ISPM-15 treated wood. ISO 6780 lists six footprints recognized for intercontinental use:
| Size (mm) | Size (in, approx.) | Where it is common |
|---|---|---|
| 1200 x 800 | 47.24 x 31.50 | Europe (EUR/EPAL 1) |
| 1200 x 1000 | 47.24 x 39.37 | Europe, Asia, UK |
| 1219 x 1016 | 48 x 40 | North America |
| 1165 x 1165 | 45.9 x 45.9 | Australia |
| 1100 x 1100 | 43.3 x 43.3 | Japan, Korea |
| 1067 x 1067 | 42 x 42 | North America, Europe, Asia |
See export shipping and ISPM-15.
Common sizes by industry
These pairings are widely cited in industry sources and are a good starting point, not a rule.
| Size (L x W, in) | Commonly used for |
|---|---|
| 48 x 40 | Grocery, consumer goods, general retail |
| 42 x 42 | Telecom, paint |
| 48 x 48 | Drums (four 55-gal) |
| 40 x 48 | Military, cement |
| 48 x 42 | Chemical, beverage |
| 40 x 40 | Dairy |
| 48 x 45 | Automotive |
| 44 x 44 | Drums, chemical |
| 36 x 36 | Beverage |
| 48 x 36 | Beverage, shingles, paper |
Worked example: a drum load
Four 55-gallon drums sit in a 2 x 2 square. A 55-gal drum is roughly 23 in across, so the square is about 46 x 46 in. A 48 x 48 pallet fits with a small margin and no overhang, which is why it is the usual drum size. The deck also needs tight gaps so drum chimes cannot drop between boards; palletdesign.ai's drum template uses 9 top boards and 4 stringers for that reason. See drum pallets.
When to go custom
A custom pallet makes sense when the product is long (lumber, pipe, doors), unusually heavy, or has a footprint far from any standard. Wood pallet mills cut to size, so a custom footprint mostly changes the cut list, not the process. Plan for how it will fit trucks, racks and equipment before committing.
Quick decision checklist
- Does the load fit with no overhang?
- Does it fit your trailer or container in a sensible pattern?
- Does it fit your racks and handling equipment?
- Does the receiver or pool require a size?
- Is it going overseas?
Questions
- What is the most common pallet size in the US?
- 48 x 40 in (1219 x 1016 mm), the GMA footprint used across grocery and consumer goods. Industry summaries of ANSI MH1 put 48 x 40 and 40 x 48 together at over a third of pallets produced.
- Should my product overhang the pallet?
- No. Overhang removes support from carton corners and walls and exposes product to damage. Size the pallet to the load or the load to the pallet.
- What pallet size should I use for export to Europe?
- Usually 1200 x 800 mm or 1200 x 1000 mm, heat treated to ISPM-15. 48 x 40 in pallets also travel to Europe, but may not suit the receiver's racks and equipment; ask the consignee what their handling system expects.
- What size pallet holds four 55-gallon drums?
- A 48 x 48 in pallet is the usual choice, with tightly spaced top boards so drum chimes cannot drop between them.