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! 

Organize Your Shipping Systems With Palletization Software

Palletization software is a vital part of supply chain operations and is designed to help with the process of placing items to be shipped onto pallets. The software automates what has historically been a manual and time-consuming task, ensuring that goods are arranged efficiently and securely on pallets to maximize space, reduce the risk of damage, and improve overall handling.

What is palletization

Palletization is the process of stacking goods or materials onto a pallet, a flat structure designed to support and stabilize them during storage and transportation. The main purpose of pallet building software is to organize the handling, storage, and movement of goods, making them easier to transport by forklifts, trucks, and other machinery. When pallets were originally introduced, the impact on material handling was dramatic.

Benefits of palletization

Faster delivery

Using pallets as a base for goods allows them to be loaded and unloaded far more quickly and efficiently, saving hours of human resources, reducing labor costs, and enabling a faster turnaround and transportation of products.

More efficient handling

Operators can insert and remove pallets more effectively, as handling equipment can stack products, reducing the number of movements required.

Lower labor costs

Labor requirements are reduced dramatically with palletization. Moving fully loaded pallets allows warehouse workers to move a greater volume of goods during each shift.

Protection of perishable goods

Palletization is particularly important for perishable goods that must be kept refrigerated. Using pallets allows these goods to be moved more quickly across unrefrigerated areas, and they can be loaded and unloaded more quickly.

Lower risk of damaged goods and freight loss

Proper palletization reduces damage to goods, protecting items and ensuring that products remain in perfect condition until the pallet is unloaded and ready for the next part of the supply chain. Items secured on pallets are bound together with plastic wrap, strapping, or both, so the chance of items falling off are low.

Warehouse staff safety

When items are palletized correctly, the pallet is stable, reducing the chance of injury to workers.

Warehouse storage optimization

Material handling is more efficient, enabling better optimization of warehouse storage, since one key factor in optimizing transportation is stackability.

Better inventory control

Palletizing loads enables better inventory control, as it is easier to monitor each SKU. Logistics managers can gauge a product’s stock level at a glance since they will know the number of products stored on each pallet.

Versatility

Usually, goods loaded onto pallets are stacked on top of one another in columns, resting directly on the item below. However, load strength and stability considerably increase when pallets are loaded in an interlocking pattern. Achieving the best loading pattern is not easy. Additionally, some goods are not suitable for palletization. These include long and thin items or irregularly shaped items that will not stack easily.

Choosing the best way to palletize

pallet loading

You can choose from a variety of palletization methods, as long as you keep stability in mind. The following tips will improve your palletization process:

  • Use cartons or boxes: Opt for regular-shaped cartons or boxes to ensure goods can be neatly stacked, resulting in more even loading.
  • Fill to max capacity: Pack the boxes as full as possible within weight and size limits.
  • Ensure even stacking: Avoid uneven stacking or bulging loads to maintain stability, and be sure to distribute items on the pallet evenly by weight.
  • Create a compact structure: Aim for a compact and uniform load structure for enhanced stability, without any items extending past the pallet base.
  • Wrap the load with transparent film: Secure the load by wrapping it in transparent film to protect the goods and keep them together.
  • Use strapping for additional  security: Consider using strapping to further secure the load and bind the goods together.

Consider pallet characteristics

Pallets are available in several standard sizes, helping optimize supply chain operations. A standard pallet is 40 x 48 x 5 inches, and most shipping companies base their freight charges on pallet volume. Using pallets can add 20% 30% volume to a shipment, so proper optimization is essential to ensure the pallets achieve maximum volume. Most companies use standard-sized boxes that are easier to stack without wasting space, but this isn’t possible for every order.

Pallets can be made from different materials, depending on the goods to be shipped. These include pallets made from wood, metal, or plastic. Pallets can also be selected according to the storage systems available in the warehouse, the handling equipment that can be manual or automatic, and facilities available at supplier locations.

Using blackbox logistics pallet loading software

MagicLogic BlackBox software includes a separate optimization engine developed specifically for palletization, including complex mixed-case pallet stacking. Our palletizing software can build layers and semi-layers. It can also automatically switch to free stacking when required. The main aim of our palletization engine is to achieve excellent pallet stability, maximum fill quality, and maximum load stability. It supports manual pack stations and robotics.

These days, more companies are choosing to automate or semi-automate their logistics operations, and BlackBox can provide packing sequences suitable for robotics. Robotics is especially useful for packaging pharmaceutical goods and the food industry, ensuring goods remain clean and hygienic during palletization.

Our BlackBox palletization software includes configurable parameters for different end-of-arm tools and approach points, allowing users to achieve true mixed case robotized palletization. Our R&D team spent considerable time solving this difficult problem effectively and is rightly proud of this achievement.

Easy to integrate with your WMS/TMS

Wir haben unsere BlackBox so konzipiert, dass sie für jedes System konfiguriert werden kann, das Daten nach einem Standardschema generiert, und verwenden leistungsstarke APIs, die sicherstellen, dass Systemintegratoren innerhalb weniger Tage betriebsbereit sind.

Custom solutions available

Over half of our business focuses on providing custom solutions to meet customers’ specific requirements. Many of our customers need to ship products that must be packed in a certain way to ensure they arrive in perfect condition and are accepted by the end-user. We specialize in finding solutions for tricky problems using our decades of experience and knowledge gained within the supply chain industry. For more information you can reach out to our customer success team.

Mit dem Boom im eCommerce Schritt halten

Anyone who ordered gifts for the recent holidays will know the supply chains are under severe strain at the moment, and many packages failed to arrive on time. While eCommerce has grown significantly over the past few years, there is nothing like a pandemic to bring this into sharper focus. With increasing numbers of people forced to shop online for the foreseeable future, businesses need to adopt a more digitized platform to reach customers successfully, a transformation that is not without its challenges.

Ensuring a Timely Delivery

Customers expect orders to arrive quickly, and a strong eCommerce platform is needed to accomplish this, including excellent logistics support. Good load planning software can make sure a load is packed more accurately, so items to be delivered first are easily accessible.

Reducing Shipping Charges

Paying zero delivery fees or only a minimal charge is becoming the norm, even while customers expect faster delivery times. However, shipping costs have increased, and offering free shipping can eat into the bottom line significantly. Some companies will offer free shipping as standard for orders over a certain threshold, but making sure orders are packaged correctly can greatly reduce shipping costs, using appropriately sized cartons and less costly fill material. The most sophisticated Cartonization software in eCommerce can select the correct carton and calculate shipping costs almost in real-time.

Another option is to include shipping in the price and include any custom fees for international shipments. The order can clear customs more quickly, and customers receive their order more promptly and without the fear of paying unknown customs costs.

Reverse Logistics

It is important to consider reverse logistics and to decide if customers are responsible for the cost of returns or how to reduce these costs. One option is to use 3PL partners with their own warehouses and logistics operations. Otherwise, one way to reduce the number of returns is by ensuring each order is handled properly. When an order is correctly picked and packed, not only are shipping costs reduced, but the risk of damage to these items is also lower.

The Importance of Using the Right Logistics Software

MagicLogic load planning software is developed in-house with one goal in mind; to provide companies with the most powerful load planning software available today. Cube-IQ® is our state-of-the-art load planning software program. It is intuitive to use and has a complete database engine built-in. Our BlackBox® optimizer provides Cartonization for eFulfillment and Mixed Palletization using robotics. It optimizes carton selection, order after order.

Our software solutions are helping companies to increase efficiency and save time and money every day. Read our recent case study for True Manufacturing to learn more.

Paletten, Palettierungssoftware und die Lieferkette

Wir neigen dazu, Paletten als selbstverständlich anzusehen, da sie überall zu finden sind und für Unternehmen ein Ärgernis darstellen können, sobald sie entladen sind. Sie sind jedoch ein wichtiger Bestandteil der Lieferkette, und die Versorgung mit Paletten wird beeinträchtigt, wenn sie zu lange an einem Ort bleiben. Allein in den Vereinigten Staaten sind schätzungsweise zwei Milliarden Paletten im Umlauf, und über 90 % der Waren werden auf Paletten versandt. Palettierungssoftware sorgt dafür, dass die Paletten optimal und sicher beladen werden. Eine schlecht beladene Palette führt zu beschädigten Waren und einer instabilen Ladung und kann natürlich auch wertvollen und teuren Platz verschwenden.

Paletten gibt es zwar schon seit Jahrzehnten, aber sie sind für die Lieferketten wichtiger denn je, vor allem weil die Lager zunehmend automatisiert werden. Die Notwendigkeit, Paletten im Umlauf zu halten, war noch nie so wichtig wie in den letzten fünfzehn Monaten, als die Verbrauchernachfrage nach Papierwaren, Reinigungsmitteln, Lebensmitteln und Getränken exponentiell anstieg. Die Verweilzeit, d. h. die Zeit, die eine Palette benötigt, um zur Verwendung angeliefert, mit Produkten beladen und ausgeliefert zu werden, bevor sie zur Wiederverwendung zurückgegeben wird, bereitet den Verladern besonderes Kopfzerbrechen. Doch die heutigen Paletten werden dank neuerer Technologien immer intelligenter.

Paletten können mit Barcodes und RFID-Tags versehen werden. RFID-Etiketten sind besonders nützlich für Unternehmen, die ihre technischen Systeme noch nicht integriert haben, da sie leicht über verschiedene Systeme hinweg verfolgt werden können. Sie ermöglichen außerdem einen einfachen Rückruf der Produkte, falls erforderlich.

Auch die für die Herstellung von Paletten verwendeten Materialien ändern sich. Obwohl traditionelle Holzpaletten immer noch verwendet werden, sind Kunststoffpaletten für automatisierte Systeme zunehmend gefragt. Sie halten länger, haben keine Nägel oder gebrochenen Bretter und hinterlassen keinen Staub und keine Rückstände, die die reibungslose Automatisierung beeinträchtigen oder Produktschäden verursachen könnten. Außerdem sind Kunststoffpaletten leichter zu reinigen und ideal für die Welt nach der Pandemie - und sie können nachhaltig produziert werden.

Kunststoffpaletten können aus Produktions- oder Verpackungsabfällen hergestellt werden. Wenn sie das Ende ihrer Lebensdauer erreicht haben, können sie zermahlen und zu neuen Paletten verarbeitet werden. Holzpaletten haben in der Regel eine begrenztere Lebensdauer, und für ihre Herstellung und ihr Recycling werden wertvolle Ressourcen benötigt. Jeder, der in letzter Zeit das zweifelhafte Vergnügen hatte, Holz zu benötigen, wird feststellen, dass die enormen Preissteigerungen den Umstieg auf Kunststoffpaletten noch attraktiver machen.

Da die Automatisierung zur Norm wird, trägt die Hochgeschwindigkeitspalettierung dazu bei, dass jede Palette ihr Geld verdient. Dies ist ein Bereich, in dem MagicLogic mit seiner fortschrittlichen Software für die Mischpalettierung helfen kann.

Die Leistung der BlackBox Palettierungssoftware nutzen

Die BlackBox-Ladeoptimierungssoftware verfügt über eine separate Engine, die speziell für die gemischte Palettierung entwickelt wurde. Sie umfasst die Bildung von Lagen, Halblagen und eine automatische Umschaltung auf freie Stapelung, falls erforderlich. Das Hauptziel unserer Mischpalettierungs-Engine ist die Palettenstabilität, d. h. die Erzielung maximaler Füllqualität und maximaler Ladungsstabilität. BlackBox kann auch eine robotertaugliche Stapelsequenz bereitstellen, einschließlich konfigurierbarer Parameter für verschiedene End-of-Arm-Tools und Anfahrpunkte. Möchten Sie mehr erfahren? Lesen Sie mehr über BlackBox und seine Möglichkeiten auf unserer Website. Kontaktieren Sie uns noch heute für eine Software-Demonstration.

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