What Pallets Are Most Efficient for Shipping Containers
Pallet efficiency in the context of shipping means how effectively a specific type of pallet can utilize the available volume and carrying capacity of a container while considering safety, economics, handling, and compliance with international standards. The main goal is to minimize unused space (“dead volume”) while not exceeding the permitted weight. The choice of the right pallet directly affects the shipping cost per unit of goods and overall competitiveness in the global market.
Key efficiency factors:
- Pallet dimensions vs. internal container dimensions: The ideal arrangement is one that fills the width and length of the container without gaps.
- Pallet material: Wooden and plastic pallets have different weights, durability, hygiene properties, and regulatory requirements.
- Weight limits: Each container has a maximum “payload” that cannot be exceeded.
- Type and nature of goods: Fragile/hygiene-sensitive goods require specific solutions.
- International regulations: Particularly ISPM 15 for wooden pallets.
Standard dimensions of shipping containers
To optimize loading, it is essential to know the exact internal dimensions of containers:
| Container Type | Internal Length (mm) | Internal Width (mm) | Internal Height (mm) | Volume (m³) | Max. Carrying Capacity (kg) |
|---|---|---|---|---|---|
| 20′ DC (Dry Container) | 5902 | 2350 | 2392 | 33.2 | 21,770 |
| 40′ DC (Dry Container) | 12032 | 2350 | 2392 | 67.7 | 26,780 |
| 40′ High Cube | 12032 | 2350 | 2697 | 76.3 | 26,512 |
| 45′ High Cube | 13556 | 2350 | 2697 | 86 | ~27,000 |
| Pallet Wide 40′ | 12032 | 2450 | 2392 | 71 | approx. 27,000 |
Note: Pallet Wide containers have approximately 10 cm greater internal width for more efficient pallet arrangement.
Types of pallets and their efficiency in shipping containers
Europalette (EPAL/EUR) – European standard
- Dimensions: 1200 x 800 mm
- Weight: approx. 22–25 kg (wooden), 15–20 kg (plastic)
- Capacity in containers:
- 20′ container: 11 pcs
- 40′ container: 24–25 pcs
- 40′ Pallet Wide: up to 30 pcs
- Arrangement: Pallets can be stacked alternately, allowing nearly perfect space utilization.
- Advantages: Optimal aspect ratio for European and container transport, easy handling.
Industrial pallet (ISO/FIN/UK)
- Dimensions: 1200 x 1000 mm
- Weight: approx. 25–30 kg (wooden)
- Capacity in containers:
- 20′ container: 9–10 pcs
- 40′ container: 20–21 pcs
- Arrangement: Two pallets side by side on the shorter side, however approx. 35 cm of unused space remains.
- Suitability: Preferred rather in the UK, Asia, and certain industrial sectors.
American pallet (GMA)
- Dimensions: 1219 x 1016 mm (48″ x 40″)
- Weight: approx. 16–20 kg (wooden)
- Capacity in containers:
- 20′ container: 9 pcs
- 40′ container: 20–21 pcs
- Disadvantage: Significantly less efficient space utilization in European containers.
Comparative table of dimensions and capacities
| Pallet Type | Dimensions (mm) | 20′ Container (pcs) | 40′ Container (pcs) | Pallet Wide 40′ (pcs) | Space Efficiency |
|---|---|---|---|---|---|
| Europalette | 1200 x 800 | 11 | 24-25 | up to 30 | Very high |
| Industrial | 1200 x 1000 | 9-10 | 20-21 | 23-24 | Medium |
| American (GMA) | 1219 x 1016 | 9 | 20-21 | 21-22 | Low |
Pallet Wide containers: Maximum from every centimeter
Special Pallet Wide containers are designed for maximum space utilization when transporting Europalettes:
- Internal width: approx. 2450 mm
- Arrangement: 2 Europalettes (2 x 1200 = 2400 mm) side by side without gaps; or 3 Europalettes on the shorter side (3 x 800 = 2400 mm).
- Result: Nearly zero unused space; capacity increase of up to 20%25.
- Use: Particularly advantageous for transporting large-volume shipments of goods on pallets within Europe.
Pallet material: Wooden vs. plastic
Wooden pallets
- Advantages:
- Low acquisition costs
- High carrying capacity (up to 1500 kg)
- Easy repairability
- Recyclability
- Disadvantages:
- Mandatory treatment (ISPM 15) for international transport outside the EU
- Susceptibility to moisture, mold, and pests
- Variable weight (affects planning)
- Hygiene limitations (unsuitable for food and pharmaceuticals)
- Use: One-way transport, non-demanding goods, export outside the EU (with ISPM 15).
Plastic pallets
- Advantages:
- Long lifespan (up to 10 years in pooling systems)
- Constant weight and dimensions (facilitates automation)
- Easy washability and disinfection
- High resistance to moisture, chemicals, and pests
- No need for ISPM 15
- Disadvantages:
- Higher acquisition price
- Difficult repairability (usually only recycling)
- Use: Repeated use, closed logistics loops, hygiene-sensitive goods.
Loading efficiency: Practical tips and trends
- Arrangement optimization: Always use placement planners to minimize gaps and account for the actual height and overhang of goods on the pallet.
- Stackability: If the nature of goods permits, stacking pallets is essential for maximizing volume utilization. Always check the maximum container height and pallet carrying capacity.
- Safety: Pallets must be secured against shifting (strapping, dunnage) – especially in maritime transport.
- Most common mistakes:
- Using an unsuitable pallet type for the given container.
- Insufficient securing of goods on the pallet.
- Underestimating pallet weight (affects total payload).
- Ignoring ISPM 15 when exporting outside the EU.
- Modern trends:
- Pallet pooling – sharing plastic pallets among multiple companies in a closed loop.
- Lightweight plastic pallets for air and combined transport.
- Ecological innovations: composite, paper pallets for one-way shipments.
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