Pallets aren’t the most exciting part of your warehouse, but choosing the right ones can make a real difference. The wrong format, weight capacity, or material can slow down your operations, damage your products, or mess with your storage setup.
You’re not just picking a platform to stack boxes on. You’re making a decision that affects how smoothly your goods move, how safe your storage is, and how well your warehouse runs day to day.
In this guide, we’ll walk through the key things you should check before ordering your next set of pallets. Let’s make sure you get the ones that actually work for your space, your team, and your business!
Start with Pallet Compatibility
A quick format check can save you from future warehouse issues.
Understand entry types
Let’s begin with something easy to overlook: how your pallet can be picked up. Some pallets can only be picked up from the front or back, and these are called 2-way pallets. Others are a bit more flexible and can be lifted from any side. Those are 4-way pallets.
If your space is tight or your team needs to grab pallets from different angles, 4-way options make things a lot easier and cut down on wasted time. You won’t need to reposition loads just to grab them.
On the other hand, if your storage layout is predictable and always approached the same way, 2-way pallets can still work.
Match the pallet size to your region
Standard pallet sizes vary by location, and using the wrong one can throw off everything from loading docks to automation systems.
If you’re in the EU, the Euro pallet (800 x 1200 mm) is the go-to option. For the UK, US, or Japan, the 1000 x 1200 mm format is more common.
Make sure your choice fits your region’s systems, especially if your warehouse uses conveyors, automated lifts, or pallet flow racking.
Think About Storage: On the Floor or Up High?
How and where you store goods will influence which pallet works best.
Pallets for floor storage
If you’re storing pallets directly on the ground, accessibility and durability matter most. Pallets need to sit flat and handle repeated movement by pallet jacks or forklifts. This setup is often used in fast-moving warehouses where stock is constantly in and out.
For floor-based operations, systems like the Modula Pallet can be helpful. This system keeps pallet movements at ground level, optimizing vertical space and reducing the risks linked to lifting and storing at height.
Pallets for racking systems
Storing pallets on racks comes with a different set of needs. The pallet must be strong enough to support the load without bending or warping over time. Racking also means that the pallet must sit safely across beams or shelves, so size and design consistency matter.
Block pallets tend to work better for racking compared to stringer pallets, thanks to their added stability. If you’re using narrow aisle racking or high bay storage, you’ll want to double-check pallet specifications before committing.
Add Your Own Operational Needs to the Mix
No two warehouses work the same way, and your pallet choice should reflect that.
Start by thinking about your equipment. If you’re using automated systems, forklifts with specific fork widths, or narrow pallet jacks, you’ll need pallets that fit your gear. An inch too wide or too tall can cause unnecessary delays. Or worse, damage.
You should also weigh cost against how long you expect the pallets to last. Custom pallets might sound like a good idea, but they usually cost more and aren’t always compatible with standard systems. If your operation focuses on sustainability, look into reusable or recycled materials.
And if your priority is budget, stick with standard formats that are easier to replace or mix into your existing system.
Conclusion
Choosing the right pallet might seem like a small warehouse detail, but this decision affects how smoothly your entire operation runs.
From size and weight capacity to storage conditions and return logistics, every part matters. The more you understand your needs, the easier it gets to pick a pallet that works with your systems, not against them.
So take a closer look at your setup, think through the day-to-day handling, and choose pallets that support your process, your products, and your team. It’s a simple change that can make a big difference.
Blog as received in the mail.
