How to Protect a Pallet During Shipping: The Complete Guide
Shipping a pallet isn’t as simple as stacking boxes and hoping for the best. Without proper protection, loads shift, boxes crush, and damage claims pile up. The right protection strategy depends on factors like weight, fragility, transportation method, and environmental exposure. Let’s break it down.
1. Corner Boards: Reinforcing Edges and Vertical Strength
- Made of cardboard, plastic, or metal.
- Protects edges from crushing and improves stacking strength.
- Helps distribute tension from strapping and stretch wrap.
Best for: Fragile loads, stackable pallets, shipments under stretch wrap.
2. Tier Sheets: Preventing Slipping Between Layers
- Flat sheets placed between pallet layers.
- Made from fiberboard, corrugated cardboard, plastic, or paper.
- Prevents layers from shifting, increasing stability.
Best for: Stacked boxes, mixed-product pallets, and anything prone to slipping.
3. Stretch Wrap: The First Line of Defense
- Wraps tightly around a pallet to hold the load together.
- Options include hand-wrap, machine-wrap, and high-performance films.
- Prevents load shifting and protects against dust and moisture.
Best for: Most general shipments, especially those not using straps or bands.
4. Shrink Wrap: More Than Just Stretch Wrap
- Requires heat to shrink and conform around the load.
- Offers a tighter hold than stretch wrap.
- Provides added protection against dust, moisture, and tampering.
Best for: High-value goods, export shipments, and products needing extra security.
5. Strapping (Plastic or Metal Bands): Securing Heavy Loads
- Polypropylene, polyester, or steel bands used to cinch loads together.
- Often paired with buckles or crimped seals.
- Keeps large, heavy, or irregularly shaped loads stable.
Best for: Heavy shipments, machinery, and loads that need extra compression.
6. Dunnage Air Bags: Filling Empty Spaces for Stability
- Inflatable bags that prevent loads from shifting inside a trailer or container.
- Made from kraft paper, polywoven material, or vinyl.
- Can withstand significant pressure and absorb impact.
Best for: Shipments in containers, railcars, or dry vans with empty spaces.
7. Pallet Covers: Extra Protection Against Elements
- Plastic or woven fabric covers placed over the entire load.
- Shields from dust, moisture, and UV exposure.
- Available in shrinkable or non-shrinkable varieties.
Best for: Products sensitive to moisture or dirt, outdoor storage.
8. Foam and Cushioning: Shock Absorption
- Foam inserts, bubble wrap, or molded pulp used inside the load.
- Absorbs impact and prevents internal movement.
- Reduces damage for fragile or irregularly shaped items.
Best for: Electronics, glass, ceramics, or anything delicate.
9. Anti-Slip Mats and Sheets: Keeping Pallets from Sliding
- Placed under the pallet or between layers to increase friction.
- Prevents load shifting due to vibrations or braking.
- Often reusable and environmentally friendly.
Best for: Shipments on smooth truck or container floors, stacked loads.
10. Edge and Corner Protectors: Preventing Strap Damage
- Plastic or cardboard pieces placed under strapping.
- Prevents strapping from cutting into boxes or crushing corners.
- Helps distribute pressure more evenly.
Best for: Loads secured with heavy strapping, delicate boxed goods.
Choosing the Right Protection
No single method covers everything. The best approach depends on what you’re shipping and how it’s being handled. Here’s a quick guide:
| Risk | Best Solution(s) |
|---|---|
| Load shifting | Dunnage air bags, strapping, stretch wrap |
| Edge and corner damage | Corner boards, edge protectors |
| Moisture exposure | Pallet covers, shrink wrap |
| Crushing from stacking | Corner boards, tier sheets |
| Internal movement | Foam, cushioning materials |
| Slipping between layers | Tier sheets, anti-slip mats |
The key is using the right combination. A mix of stretch wrap, strapping, and corner protection can significantly reduce damage risk.
Protecting a pallet isn’t just about reducing damage—it’s about increasing efficiency and reducing costs. A well-secured pallet speeds up loading and unloading, reduces claims, and ensures products arrive in good shape. The right materials make all the difference.
Which of these protection methods do you currently use? Are you seeing damage issues that need a better solution?