Choosing the right pallet size, either to standardise across your business or for a one-off shipment, may seem simple – just get one that can fit whatever you’re transporting, right?
But it’s actually one of the fundamental decisions you can make for your logistics operation. The pallet – quite literally – underpins all your supply chain. The size and type of pallet will affect how efficiently you can store and handle goods. And a sub-optimal or plain incorrect pallet size can waste space, raise freight costs, cause handling issues with automated systems and even lead to product damage.
In this blog, we’ll look at how you can select the best pallet size for your business needs. We’ll cover common pallet sizes, what you should consider when selecting a pallet size and how getting it right can optimise your operations.
Why Pallet Size Matters
The purpose of a pallet is to improve the efficiency of logistics – instead of moving the load or goods by themselves, the pallet becomes the load. And pallets of a standardised design are much easier to handle (think of the time taken to load a dozen boxes into a container one by one, compared to loading all of them in one go on a pallet). Pallets cut the time and labour needed to handle goods by around 90 per cent!
A pallet of the right size means your products will be properly supported and fully compatible with transport and storage systems. Whether it’s the size of the door on a hired van or a fully automated warehouse, only pallets of the right size will gain these benefits. A pallet that’s too large will waste space (so you are effectively paying to transport empty air around!) while one that’s too small may not safely support and protect your load.
Choosing that size comes down to balancing three factors – the dimensions of your product, the efficiency of transport and the standards in your region. Align your pallet size to these and you’ll ensure that goods are stored safely, handled easily and transported at the most effective cost.
Understanding Common Pallet Sizes
One thing making this decision more complicated is that, for all the advantages of a standardised pallet size, and despite the global nature of the logistics industry, there isn’t just one pallet standard. The pallet spread across different regions of the world and different industries before international standards could be developed, so there are several pallet sizes in use. Which one is considered ‘standard’ depends on where in the world you are operating and, sometimes, what industry you’re operating in or what the product is. Knowing these details is the first step in choosing the right pallet.
In Europe, the standard EPAL (European Pallet Association) or ‘Euro’ pallet is predominant. At 1200mm x 800mm, this compact but sturdy pallet is designed to fit European transport vehicles, business premises and warehouse shelving.
In the UK, the ISO pallet is the most common. So much so that it’s usually just called a ‘standard pallet’. This is 1200mm x 1000mm, so it’s slightly larger than the Euro pallet. It’s ideal for bulkier goods and is often used in manufacturing, industrial applications and large-scale retail distribution.
In other markets and regions, there are other different standards to be aware of. In North America, the Grocery Manufacturers Association pioneered the use of pallets in the 1950s, with the result that the 48” x 40” (1219mm x 1016mm) ‘GMA pallet’ is predominant.
Meanwhile, on the other side of the Pacific, Asia favours a square 1100mm x 1100mm pallet and Australia uses a slightly larger square design of 1165mm x 1165mm.
For businesses operating internationally, it’s crucial to at least be aware of these differences. When exporting to different regions, you should consider adapting your choice of pallet to suit local requirements, or at least confirming with the receiver if there are any restrictions on the pallets they can handle. You can then decide whether to select a pallet to suit those local standards, or even one that is compatible with multiple standards.
What Is the Most Common Pallet Size?
So those are the major types of pallets in use around the world. But what is the most common pallet size? As the information above suggests, it depends on where in the world you are operating.
For the UK, the Euro pallet and the ISO ‘UK Standard’ predominate, and they’re fairly equal in popularity. It shouldn’t be that surprising that businesses that ship goods to and/or from Europe use more Euro pallets, while those dealing with internal or domestic transport, especially industrial and retail distribution, use the UK Standard pallet. Heavier or bulkier items benefit from the slightly wider base, giving more stability and better load protection.
INKA Pallets offers both of these sizes in a wide range of materials and designs. From our famous plastic pallets (in lightweight nestable models to heavy-duty racking pallets) to presswood pallets. With this choice of pallet types and sizes, every customer can be sure of finding the ideal match for their operations.
Factors to Consider When Choosing a Pallet Size
There is more to selecting the right pallet dimensions than just matching the size of your product to the footprint of the pallet. You need to consider how your goods are packaged, how they’re stored and how they are shipped. Here are some of the other key factors you should consider when determining your ideal pallet size.
1) Product Dimensions and Packaging
While it is not the only thing to consider, the size and shape of your products or goods are still the primary driver of what the ideal pallet will be. Your goal should be to optimise the use of space by ensuring that the pallet surface area matches the footprint of your load as closely as possible. If the pallet is too small, your products will overhang the edges of the pallet and they’re much more likely to be damaged during transport. If the pallet is too big, there will be unused empty space, which wastes capacity.
It can be easier to get this optimal balance by grouping smaller products into larger, standardised units. This can make it easier to use a single pallet size across your supply chain.
2) Weight and Load Distribution
When it comes to weight, the weight of the load will affect your pallet choice, as this must be within the load ratings (static and dynamic) of the pallet. But you must also consider how the weight is distributed across the pallet’s surface.
Larger pallets can have lower weight ratings than smaller ones, as they have larger unsupported decks between the structural runners. You don’t want to put a heavy load in the middle of a large pallet where there isn’t sufficient support. Heavy products will need heavy-duty pallets, made with extra structural support that can handle these loads without warping or cracking.
For example, INKA’s heavy-duty plastic pallets can handle dynamic loads up to 2250 kg and static loads up to 7000 kg, making them suitable for demanding industrial environments.
3) Storage and Handling Systems
Your warehouse setup is another key consideration when choosing a pallet size. Do your conveyors or racking systems require pallets of particular dimensions, or can they handle a range of types? What widths of pallets are your forklifts set up to handle?
The advantages of pallets are all in allowing standardisation, and this applies to all the handling equipment and procedures in the supply chain too. Adopting a single pallet size within your facility improves efficiency, reduces labour and reduces handling risks. Automated systems offer huge benefits in speed, efficiency and accuracy, but they are usually optimised for a single size of pallet, not to mention benefiting from the durability and consistency of plastic pallets.
4) Transport Method and Destination
If your goods are shipped by road, sea, or air, pallet size can affect transport costs and compliance. Smaller Euro pallets often fit more efficiently in European trucks, while the slightly larger UK pallets are better suited for domestic haulage. The chemical and construction industry favours a specific ‘CP3’ pallet – a square 1140mm x 1140mm – for carrying standard 200 litre/44-gallon drums of liquid.
For export operations, always confirm that your pallet dimensions meet destination country standards. Using the wrong size can cause compatibility issues with local racking or lead to repacking delays at customs.
5) Material and Environment
While size is key, the pallet material also plays an important role. Plastic pallets are ideal for environments requiring hygiene, consistency and durability. They don’t absorb moisture or change weight in different conditions, unlike wooden pallets, which can gain or lose several kilograms when exposed to humidity.
In industries such as food, pharmaceuticals and clean manufacturing, plastic pallets also eliminate the risk of contamination from splinters or nails. So they offer a safer and more hygienic solution.
Matching Pallet Size to Industry Use
Different industries rely on specific pallet sizes to optimise operations. For instance, Euro pallets are common in retail and FMCG supply chains because they fit perfectly into standard European trucks and racking systems. The UK Standard 1200x1000mm pallet is widely used in heavier industries such as construction, engineering and manufacturing.
For international exporters, versatility is key. Some businesses choose to invest in multi-standard plastic pallets, designed to fit a variety of transport formats across regions. These options provide flexibility and prevent costly re-palletising when goods move between different logistics networks.
Why Choosing the Right Size Improves Efficiency
Selecting the correct pallet size can transform the efficiency of your logistics operation. By using the most common pallet size for your region, you gain compatibility across transport and storage systems, making handling faster and reducing the risk of product damage.
Right-sized pallets also improve load density, allowing more goods to fit into each container or truck. This maximises shipping efficiency and reduces transport costs. Over time, the savings from optimised pallet sizing can significantly impact your bottom line.
Conclusion
Choosing the right pallet size is essential for safe, efficient and cost-effective logistics. Understanding common pallet sizes and knowing what the most common pallet size is for your region allows you to streamline operations, reduce waste and improve overall supply chain performance.
From the compact Euro pallet (1200x800mm) to the versatile UK standard pallet (1200x1000mm), INKA Pallets provides a full range of durable, reusable and hygienic solutions tailored to your needs.
Contact INKA Pallets today to find out more about our standard and custom pallet options and discover how we can help you choose the ideal pallet size for your products.