Forklift loading two pallets onto a truck

Planning Your Load: How Many Pallets Fit in a Truck?

Are you paying for air? 

If loading pallets into a truck feels like a high-stakes game of Tetris, you’re not alone. The trouble is, when you’re loading pallets into trucks, every square inch counts. If you’re not maximizing your space, you’re essentially throwing money away. All those gaps and pockets of air inside your trailer might not seem like much at first glance, but they add up to significant inefficiencies such as higher fuel costs, more trips, and wasted resources. 

And when margins are razor-thin, you can’t afford to pay for space you’re not using. 

Unfortunately, inefficient loading doesn’t just cost you extra in shipping fees; it can lead to damaged goods and increased liability. Poorly packed trailers are more prone to shifting loads, damaged goods, accidents, or fines. On the flip side, mastering load planning can transform your logistics—reducing costs, improving safety, and boosting your bottom line. 

Let’s dive into some strategies that will help you load your pallets like a pro, minimizing that wasted space, lowering your transportation costs, and ensuring your goods arrive safely to their destinations. Let’s make sure you never heave to pay for air again. 

How many standard pallets are in a full truckload? 

On average, a 53 foot semi trailer can fit 30 standard pallets, assuming they aren’t stacked. However, this number can vary significantly based on several factors: 

  • Pallet size:  A 48” x 40” GMA (Grocery Manufacturers Association) pallet is standard, but other pallet sizes may be used, and that affects how many will fit in a trailer. 
  • Loading configuration: The pallets can be loaded straight (end-to-end lengthwise), pinwheeled (one lengthwise then one crosswise), or turned (end-to-end crosswise). This will affect how many will fit. 
  • Pallet weight: The overall weight of the pallets and their contents may limit the number of pallets due to weight restrictions on the truck. 
  • Stacking: If the pallets can be safely stacked, the number of pallets per truckload can increase up to double. 
  • Axle configuration: The specific axle configuration of the truck can influence how the weight needs to be distributed, which will impact how many pallets can be loaded. 

To provide a more precise estimate, refer to the following table that assumes the use of standard 48” x 40” GMA pallets, loaded without stacking. 

Trailer Length 48” x 40” GMA Pallet
53 feet (636 inches) 26 straight
28 pinwheeled
30 turned
48 feet (576 inches) 24 straight (tight)
26 pinwheeled (tight)
28 turned
40 feet (480 inches) 18 straight
20 pinwheeled
22 turned
24 feet (288 inches)  10 straight
12 pinwheeled
14 turned 
16 feet (192 inches)  6 straight
8 pinwheeled
8 turned 

What are standard pallet sizes? 

The 48” x 40” pallet is the most common size in the U.S. and Canada. Referred to as the GMA pallet, the dimensions were standardized by the Grocery Manufacturers Association, and the pallet is generally used for groceries and warehousing. 

Though 39% of pallets used in the U.S are custom sized, many other sizes are common throughout North America:

  • 42” x 42” or paint pallet, it’s frequently used in the telecommunications and paint industries
  • 48” x 48” perfect for transporting 55 gallon drums of liquid
  • 48” x 42” used by the chemical and beverage industries
  • 48” x 45” used in the automotive industry
  • 40” x 40” common in the dairy industry
  • 36” x 36” often used to transport bottled beverages

In Europe, pallet sizes are measured in millimeters, and the most common sizes are the EUR (1200 mm x 800 mm—also known as EUR 1, Europallet, and EPAL), the EUR 2 (1200 mm x 1000 mm—similar in size to the GMA pallet common in North America), the EUR 3 (1000 mm x 1200 mm), and the EUR 6 (800 mm x 600mm). 

How to maximize trailer space

Remember that air space you don’t want to pay for? It’s crucial to maximize trailer space to improve efficiency, get rid of that air space, and reduce shipping costs. To make the most of every inch, consider carefully how your goods are loaded, keeping in mind factors like stackability, pallet size, and the order in which items are placed in your trailer. This will also enhance the safety and security of your cargo during transit. 

These tips and strategies will help you maximize your trailer space effectively: 

    1. Stack your pallets when possible. Using the vertical space is more efficient, but if you do, it’s critical to make sure the items on the pallets are stable and secure to prevent shifting or damage during transit. Stacking properly can double the number of pallets you can fit into your trailer. 
    2. Opt for uniform pallet sizes that maximize available space. If possible, use smaller pallets for smaller shipments, which will help you be more efficient with your arrangement and reduce wasted space. Keep the configuration of different pallet sizes in mind to optimize loading patterns. 
    3. Load large and heavy items first. Placing larger and heavier items at the back of the trailer and on the bottom of the stack helps balance the trailer for safer driving. It also ensures that heavier items are securely positioned and less likely to cause damage to lighter, more fragile goods. 
    4. Load small and light items last. Seems like a no brainer, but it’s worth pointing out that filling in gaps with light and small items will ensure that no space is wasted. These items can be placed on top of heavier goods or in spaces between pallets to maximize every inch of your trailer. 

A note about weight distribution: Proper weight distribution within the trailer maximizes space but also maintains safety on the road. Unevenly distributed loads can lead to increased wear on tires, reduced fuel efficiency, and dangerous driving conditions. It’s never okay to sacrifice proper weight distribution for the sake of saving space. It’s not worth it in the long run. Make sure you understand axle weight limits, where the center of gravity needs to be, and how to avoid improper loading that could lead to accidents or fines during inspections. 

Still having issues with loading your pallets? Read these solutions to 15 common load optimization problems

The cost of inefficient loading

One of the biggest challenges in logistics is making sure each load is as cost effective as possible. Inefficient loading means wasted space and increased transportation costs, and nobody wants that. If you aren’t using your space efficiently—if your trucks aren’t fully optimized—you’re essentially paying to transport air. That jacks up fuel costs and increases your carbon footprint unnecessarily. On the flip side, higher efficiency with loading your pallets into your trucks will save on shipping costs, reduce fuel charges, and help the environment. 

Make load planning easy

Properly loading your pallets and placing them efficiently into your trucks will keep your goods safer and reduce shipping and transportation costs significantly. These tips in this article will help, but you don’t have to figure it all out on your own. The easiest way to plan your loads quickly, efficiently, and safely is to use load planning software like Cube-IQ. Our advanced load planning software is designed to handle the complexities of modern logistics so you don’t need to break a sweat. 

How does it work? Cube-IQ communicates with your other systems, plugging in all pertinent information about individual items and specific packaging rules you have in place. Our algorithm then automatically determines the optimal plan for the situation, whether you’re packing items into a carton, on a pallet, or into a truck. 

Cube-IQ plays the perfect game of Tetris so you can pack efficiently and safely, saving time, energy, and money in the process.  

Start your free trial today! 

MagicLogic Optimization Inc. Selected as 2023 Top 100 Logistics IT Provider – Our 21st Consecutive Year Receiving This Award

We are proud to announce that once again, Inbound Logistics has selected MagicLogic Optimization as a Top 100 Logistics Provider for 2023. We have now been selected for this award for 21 consecutive years. It is always an honour to receive this award, and we like to display our Top 100 badge on our website and communications with customers.

“Every April for the past 25 years, Inbound Logistics editors have selected 100 logistics technology companies that enable logistics and supply chain excellence’ explains Inbound Logistics editor Felecia Stratton. “MagicLogic Optimization Inc. was recognized for leading the way in 2023 and positioning enterprises to scale and grow. MagicLogic Optimization Inc. excels at providing solutions that drive supply chain excellence and answer IL readers’ needs for simplicity, ROI, and frictionless implementation. Inbound Logistics is proud to honor MagicLogic Optimization Inc. for continuing to offer our readers solutions that optimize logistics and supply chain excellence and drive enterprise performance.”

MagicLogic is constantly working on improving our load optimization software further and building and strengthening industry partnerships. Our recent introduction of Cube-IQ Web and hosted BlackBox solutions are proving extremely popular, with companies increasingly seeking more mobile solutions suited to today’s workforce.

R&D of existing and new products is incredibly important to us, so we can continue to cater to the changing needs of our customers. Felecia elaborates further on how our company was selected: “Top 100 Logistics IT Providers such as MagicLogic Optimization Inc. help customers navigate the complexities of global trade and expansion. MagicLogic Optimization Inc. provides the technology solutions Inbound Logistics readers need to successfully manage their global enterprises, minimize disruption damage, and adapt to changing trade currents. Accordingly, Inbound Logistics is proud to honor MagicLogic Optimization’s innovative solutions empowering global logistics and supply chain excellence.”

The Selection Process

Every April, Inbound Logistics editors recognize 100 logistics IT companies that support and enable enterprise excellence. Drawn from a pool of more than 300 companies, using questionnaires, phone calls, personal interviews, and other research, Inbound Logistics selects the Top 100 Logistics IT Providers who are leading the way to efficiency for 2023 and beyond. Editors match our readers’ fast-changing needs to the capabilities of those companies selected.  All companies selected reflect leadership by answering and anticipating supply chain leaders’ needs for simplicity, flexible pricing, ROI, and frictionless implementation.

About Inbound Logistics

Inbound Logistics is the pioneering magazine empowering demand-driven enterprises. IL’s educational mission is to guide businesses to efficiently manage logistics, reduce and speed inventory, and neutralize transportation cost increases by aligning supply to demand and adjusting enterprise functions to support that paradigm shift. More information about demand-driven enterprise practices is available at www.inboundlogistics.com

About Our Load Optimization Software

MagicLogic load optimization solutions are suitable for small to medium-sized companies and larger multinationals shipping thousands of products daily. Our Cube-IQ Load Optimization software includes our subscription-based service, where users can access the software from their smartphone, tablet or browser, and is perfect for flexible workplaces. BlackBox, our flagship product, can handle complex Cartonization and palletization, including true robotic palletization. BlackBox integrates easily with any WMS/ERP system, including legacy systems. Industry-specific solutions tailored to accommodate specific requirements are available. We also offer a custom service for companies with unique shipping requirements.
Please contact us to learn more about our software solutions and to arrange a quick demo.

20 Years in the Top 100

MagicLogic Optimization Inc. Selected as 2022 Top 100 Logistics IT Provider – Our 20th Consecutive Year Receiving This Award

We were recently thrilled to learn that MagicLogic Optimization has yet again been selected as an Inbound Logistics Top 100 Logistics IT Provider for 2022. This marks our 20th consecutive year receiving this honor. We never take this award for granted and are always proud to display the latest Top 100 badge on our website and in all communications with customers.

Inbound Logistics editors recognize 100 logistics IT companies that support and enable logistics excellence. Drawn from a pool of more than 300 companies, using questionnaires, phone calls, personal interviews, and other research, Inbound Logistics selects the Top 100 Logistics IT Providers who are leading the way to efficiency for 2023. Editors seek to match readers’ fast-changing needs to the capabilities of those companies selected.  All companies selected reflect leadership by answering Inbound Logistics readers’ needs for simplicity, flexible pricing, ROI, and frictionless implementation.

Felecia Stratton, Inbound Logistics Editor, explains: “Every April for the past 24 years, Inbound Logistics editors have selected 100 logistics technology companies that enable logistics and supply chain excellence. MagicLogic Optimization was recognized by Inbound Logistics for leading the way in 2022 and positioning enterprises for the years ahead. MagicLogic excels at providing solutions that drive supply chain excellence and answer IL readers’ need for simplicity, ROI, and frictionless implementation. Inbound Logistics is proud to honor MagicLogic for continuing to offer our readers solutions that optimize logistics and supply chain excellence.”

Supply chains worldwide have continued to be under unprecedented pressure over the past two years. These are compounded further by rising fuel costs and the rising prices of essential commodities, coupled with continuing labor shortages and with no end in sight. MagicLogic provides a suite of software solutions to ensure products are loaded more efficiently and safely, so they can arrive in pristine condition. Our innovative software solutions are designed to be intuitive, and even an inexperienced user will be up and running within just an hour or so with our tuition.

Felecia Stratton elaborates further on how they selected MagicLogic. “Implementing the best logistics technology helps large companies expand markets and drive undiscovered efficiencies. World-class solutions such as MagicLogic Optimization are force equalizers for SMEs by leveling the playing field with their larger competitors. Best-in-class logistics IT also helps today’s business logistics managers boost supply chain performance and customer service while cutting overall logistics costs. Inbound Logistics editors selected MagicLogic for its consistent ability to deliver innovative solutions empowering logistics and supply chain excellence for companies large and small.”

About Inbound Logistics

Inbound Logistics is the pioneering magazine empowering demand-driven enterprises. IL’s educational mission is to guide businesses to efficiently manage logistics, reduce and speed inventory, and neutralize transportation cost increases by aligning supply to demand and adjusting enterprise functions to support that paradigm shift. More information about demand-driven logistics practices is available at www.inboundlogistics.com

About Our Load Optimization Software

MagicLogic provides load optimization solutions for all sized companies, including those who might only load a few containers a month, right up to multinationals shipping thousands of orders each day.

Our products include Cube-IQ Load Optimization software and Cube-IQ Web, our subscription service allowing users to access our software from their tablet, browser, or smartphone no matter where they are. As workplace flexibility looks set to stay, our web version is becoming increasingly popular.

BlackBox is our flagship product, handling complex Cartonization and palletization with ease, including true robot palletization. BlackBox integrates seamlessly with any WMS/ERP system and can be up and running within a short while. We also offer industry-specific solutions tailored to accommodate unique requirements or can customize our software to suit the needs of the client. Contact us to learn more about our software solutions.

MagicLogic Optimization Inc. Selected as 2021 Top 100 Logistics IT Provider

We are delighted to announce the editorial team at Inbound Logistics has selected MagicLogic Optimization Inc. as a Top 100 Logistics IT Provider for 2021. This marks the nineteenth consecutive year MagicLogic has been chosen for this honor. Each year, we proudly display our Top 100 badge on communications with customers and on our website.

Every April, Inbound Logistics selects the Top 100 Logistics IT Providers who are leading the way in 2021. The editors make their selection using research, questionnaires, and personal interviews from a pool of more than 400 companies.

Felecia Stratton, Editor of Inbound Logistics, elaborates on how they choose the Top 100: “When choosing the 2021 Top 100 Logistics IT Providers, Inbound Logistics editors looked at excellence in optimizing supply chain, logistics, and transportation operations. Strategically, editors make their selections based on how transformative solutions impact those business activities driving integration across internal and external business processes. MagicLogic Optimization Inc. was selected because its solutions solve specific logistics challenges and improve processes, and create a ripple effect of enterprise efficiencies across the entire value chain.”

The past year has tested the strength of supply chains like never before. MagicLogic has risen to the challenge. Our team continues to solve complex logistical problems and customize our software solutions to meet the current demands and are an important part of the supply chain for many top-tier companies.

Felecia Stratton explains further how these problems have affected companies: ”The business disruptions of the past year remind businesses to focus like a laser beam on improving enterprise operations through investments in technology. The challenges are many and are now top of mind. Improving end-to-end visibility, achieving closer integration with value chain partners, finding efficient sources of transport lift, nailing down chain of custody and sustainability concerns to limit liability, inventory scalability have clearly become survival issues for many. MagicLogic was selected as a Top 100 Logistics IT Provider because its solutions address these critical needs and help companies move along the continuum to truly becoming demand driven enterprises.”

MagicLogic provides loading software designed to grow with companies, loading more and ensuring orders arrive in pristine condition. It is increasingly likely that the challenges presented by COVID-19 will change consumers’ shopping habits for good. While B2B growth remains strong, there is a continuing need for B2C solutions. Our flagship product, BlackBoxTM, integrates seamlessly with any WMS/EMS system and handles Cartonization and palletization, and ensures the correct cartons are selected for online orders in near real-time, minimizing fill material and reducing shipping costs.

About Inbound Logistics

Since its inception in 1981, Inbound Logistics’ educational mission is to illustrate the benefits of demand-driven logistics practices, give companies the knowledge to help them match the inbound flow of materials to their demand, and align their business process to support that shift. Inbound Logistics offers real-world examples and decision support to guide businesses to efficiently manage logistics, reduce and speed inventory, offset rising transport costs, and balance transport needs with demand, supporting business scalability across their value chain. More information about demand-driven logistics practices is available at www.inboundlogistics.com

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