Also known as: Palletisation, Unitisation, Pallet Loading
Palletizing is arranging cartons onto a pallet and securing them into a single stable unit for handling and transport. Correct stacking patterns, corner protection and stretch wrapping determine whether a load survives forklift handling, road vibration and container shipping.
The principle of unitisation is that many small packages handled individually will be dropped, dragged and mis-stacked, whereas one secured unit is moved by machine and handled far less. Most damage reduction in industrial shipping comes from this alone.
Stacking pattern matters more than most shippers expect. Column stacking — cartons aligned corner over corner — gives the highest compression strength because the vertical corners carry load directly. Interlocked stacking is more stable against toppling but can lose a significant share of stacking strength because corners no longer align.
Overhang is a frequent and costly error. Cartons projecting past the pallet edge lose the support of the deck beneath them and can shed a large part of their compression strength, which is why loads that "look fine" collapse in a container.
A well-built pallet load combines a correct stacking pattern, corner or angle boards at the vertical edges, adequate stretch film with proper containment force, and often a top sheet or strapping for loads that will be double-stacked.
Palletizing at a glance
| Common Indian pallet | 1200 × 1000 mm and 1200 × 800 mm |
|---|---|
| Column stacking | Highest compression strength, lower stability |
| Interlocked stacking | Better stability, reduced compression strength |
| Overhang | Avoid — sharply reduces stacking strength |
| Securing | Stretch film, strapping, angle boards, top sheet |
Common questions
Column stacking or interlocked stacking?
Column stacking is stronger vertically because carton corners align and carry the load, so use it when boxes will be stacked high. Interlocked stacking resists toppling better but sacrifices compression strength — a reasonable trade for lighter, unstable loads.
Why do palletised loads collapse in containers?
Usually carton overhang past the pallet edge, misaligned stacking that stops corners carrying load, insufficient stretch-film containment force, or humidity weakening the board during a sea voyage. Angle boards and correct pattern fix most cases.
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