9 Things You Need to Know When Choosing Pallets for Your Freight

Written By Melonie Eternicka

1. Pallet Load Capacity & Weight Limits

Not all pallets are built to carry the same weight.

  • Light Loads (under 1,000 lbs): Standard softwood pallets are fine.
  • Medium Loads (1,000–2,500 lbs): Reinforced or hardwood pallets are recommended.
  • Heavy Loads (2,500+ lbs): Block-style, hardwood, or metal pallets may be needed.
Pro Tip: Overloading a pallet shortens its lifespan and increases the risk of failure in transit.
Pallet sizes and freight dimensions

2. Pallet Sizes & Freight Dimensions

A standard 48” x 40” works for most, but not all. If your freight consistently overhangs, you could face:

  • Reclassification or reweigh fees
  • Shipment rejection or “ship at shipper’s risk” labels
  • Higher long-term costs from damaged freight
Why it matters: Properly sized pallets help prevent reclass fees and shipment delays.
Pallet material options including wood plastic and metal

3. Pallet Material Options (Wood, Plastic, Metal)

  • Wood: Affordable, versatile, and repairable. Available in new or recycled.
  • Plastic: Hygienic and moisture-resistant; ideal for food, beverage, or pharma.
  • Metal: Extremely durable and strong, but expensive and heavy.
Why it matters: Choosing the wrong material can increase costs or cause compliance issues.
Pallet entry types and handling options

4. Entry Type & Handling

  • 2-Way Entry: Forks enter from two sides only.
  • 4-Way Entry: Forklifts and pallet jacks can lift from any side.
Why it matters: 4-way entry pallets improve dock efficiency and reduce handling time.
Pallet deck board and design features

5. Deck Board & Design Features

  • Wide Deck Boards: Improve stability for fragile items.
  • Solid Decks: Prevent smaller items from slipping through.
  • Block vs. Stringer: Block pallets allow 4-way entry; stringers are more cost-effective.
Why it matters: Proper deck design reduces product damage and handling issues.
Pallet wood types including softwood and hardwood

6. Wood Type

  • Softwood (Pine): Lightweight and cost-effective for one-way shipments.
  • Hardwood (Oak): Durable and long-lasting for repeated use.
Why it matters: Wood selection impacts pallet lifespan and total cost of ownership.
New pallets versus recycled pallets

7. New vs. Recycled Pallets

  • New Pallets: Consistent strength and clean appearance.
  • Recycled Pallets: Cost-effective and environmentally friendly.
Why it matters: Recycled pallets may not meet hygiene or durability standards in all industries.
ISPM-15 heat treated pallets for export compliance

8. ISPM-15 Heat Treatment & Export Compliance

If you’re shipping internationally, ISPM-15 heat-treated pallets are required.

Why it matters: Missing HT stamps can cause customs delays, rejections, or forced re-palletization.
Proper pallet storage and maintenance practices

9. Pallet Storage & Maintenance

  • Store pallets in dry, ventilated areas.
  • Inspect and repair regularly.
  • Rotate stock to prevent aging and degradation.
Why it matters: Proper storage extends pallet life and reduces replacement costs.

Final Word

Choosing the best pallet isn’t just about cost. It’s about making sure your freight arrives safely, avoids unnecessary fees, and keeps your operation moving.

For some shippers, a standard 48” x 40” gets the job done. For others, a well-built custom pallet is the smarter long-term call.

If availability, consistency, or performance are concerns, it may be time to talk through your options with someone who understands both pallets and freight.

👉 Want a second set of eyes on your pallet setup? Request a Pallet Consultation
Melonie Eternicka
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