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. 

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. 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!