How to Calculate Cartons on a Pallet

What is the Calculation to Determine Cartons on a Pallet?

To calculate how many cartons can fit on a single pallet, use the following formula: Divide the shipment's CBM (cubic meters) by 1.5.

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Why is This Calculation Important?

This calculation is essential for estimating the number of cartons a pallet can accommodate. It's particularly useful for calculating storage costs or determining how many pallets are needed for shipping when palletizing at the origin.

Is the Result an Exact Quantity of Pallets?

No, the result is an approximate estimate. The exact number of pallets required can only be determined after the boxes are palletized.

How Can This Information be Helpful for Businesses?

• Helps in planning storage space and costs.
• Aids in optimizing the shipping process by determining pallet requirements.
• Useful for budgeting and logistics management.

Choose the correct pallet type to avoid repalletization at your 3PL warehouse, which comes at an added cost, or worse, get penalized by Amazon for having the wrong pallet type.

Here are the top six things you should consider before investing in pallets.

Amazon Pallet Requirements

Before shipping your inventory to Amazon, ensure that your pallets meet the following requirements:

Pallet Type

Ship your products on 40 x 48-inch, 4-way access wooden pallets.

Grocery Manufacturers Association (GMA) Pallet Specifications

The food industry, including Amazon, follows the pallet guidelines set by the Grocery Manufacturers Association (GMA), recently rebranded as the Consumer Brands Association. These guidelines ensure the fast and smooth movement of products throughout the US.

GMA guidelines divide pallets into two main groups – Grade A and Grade B – to identify differences between nearly new pallets and those with minor cracks or imperfections. In some cases, these grades are also referred to as #1 and #2. These grades are based on the pallet’s general appearance, compliance with GMA requirements, structural integrity, and the repair needed to make the pallet usable.

Within Grades A and B, several subcategories make distinctions between higher and lower quality pallets. Familiarize yourself with these classifications to better understand Amazon’s pallet requirements, so you can request the correct pallets from your suppliers or freight forwarders.

Premium Grade A or #1A: Often marketed as good as new, premium Grade A pallets have a bright wooden color with no visible signs of extensive repair. They are perfect for shipping and storing food and grocery items and for in-store visual merchandising. Some grocery stores use premium pallets as part of their retail display to attract shoppers' attention.

Melon Grade or #1B: These pallets are almost similar to #1A with no obvious signs of repair, but they may have minor damage or discoloration, making them slightly inferior to premium Grade A pallets.

Regular Grade A or 1R: Also called Regular Grade, these pallets are refurbished to achieve like-new condition by replacing damaged or broken deckboards with good-quality recycled boards. This makes 1R pallets more affordable than Premium A and Melon grades, although they generally have a more worn appearance.

Premium Grade B or #2: These pallets may have had repairs done to one of the stringers, like adding a sturdy piece of wood for extra support. These repairs should make premium B grades durable and stable enough to carry loads without trouble.

Standard Grade B: The lowest standard grade offered by many manufacturers, B grades are the cheapest. However, some parts may be cracked or missing, requiring extensive repair.

To stay compliant with Amazon’s pallet requirements, follow these guidelines:

Ship units on GMA Standard B Grade or higher pallets that have:

• 6 or 7 top deckboards, depending on the width.
• 4 access points.
• At least 4 bottom deckboards.
• 3 stringers.
• No visible repairs to the stringers.

Ship grocery items on GMA 1A Grade pallets that have:

• 7 top deckboards.
• 5 bottom deckboards.
• 4 access points.
• 3 stringers.
• No repairs to the stringers.

Ship health and personal products on GMA 1A and 1B Grade pallets that have:

• 6 or 7 top deckboards, depending on board thickness.
• At least 4 bottom deckboards.
• 4 access points.
• 3 stringers.
• Only one stringer with minor repairs.

Only use pallets in good condition. Damaged or broken pallets may be rejected by Amazon at your expense.

Pallet Height

Amazon’s maximum allowable pallet height depends on whether you're using a:

Non-Stackable Pallet

Also known as a single pallet, a non-stackable pallet can't be stacked due to the unit's shape or a "Do Not Stack" label. A single pallet freight shipment must not exceed 72 inches to be approved by Amazon.

Consider the height of the pallet itself. A standard 40 x 48-inch pallet is usually 6 inches high, leaving you with 66 inches of carton height for stacking.

Some carriers like FedEx may apply a surcharge to non-stackable freight shipments as they take up less vertical space in a truck. Check with your carrier for details.

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Stackable Pallet

A stackable pallet allows stacking multiple pallets on top of each other. You can ship on a double-stacked pallet into Amazon, but the total height, including the pallets, must not exceed 100 inches, meaning each pallet stack can be up to 50 inches high. For each stackable pallet, you have 44 inches for carton stacking due to the 6 inches of pallet height.

Pro tip: Talk with your 3PL about whether they prefer stackable or non-stackable pallets. It’s important to consider the height of your truck when palletizing, as stackable pallets might allow more units per truckload. Also, read Amazon's Seller Requirements for LTL, FTL, and FCL Deliveries.

Floor Loading

If you're considering floor loading to maximize space and reduce cost, note that it’s not suitable for all shipments. Heavy items like carpets, large appliances, furniture, or tires may be floor-loaded. However, fragile goods shouldn’t be floor-loaded to reduce the risk of damage during transport.

Amazon often rejects floor-loaded shipments that require extensive handling, such as boxes over 50lbs or those shipped in a trailer with an uneven floor. Since they require extra labor, it may also delay your inventory’s availability for sale on Amazon. Therefore, palletize your inventory as much as possible to avoid delays.

If palletizing isn’t an option, notify your carrier that the shipment will be floor-loaded. They will review and let you know if it’s accepted and any additional charges.

Work closely with your carrier to ensure your shipment meets Amazon’s Floor Loading Policy, avoiding unnecessary charges or shipment rejections.

Pallet Weight

The weight of the pallet, both stackable and non-stackable, should not exceed 1,500lbs (680kgs). To ensure efficient handling, each carton on the pallet should not weigh more than 50lbs, unless it contains a single large or oversized unit.

Pallet’s Compatibility with Your 3PL’s Handling Equipment

Pallets are either two-way or four-way, affecting how they can be lifted. For instance, forklifts can't enter a two-way pallet from the sides, while four-way entry pallets can be accessed from all sides. This is crucial for some warehouses, like Amazon, which only use four-way access pallets for efficiency and convenience.

Ensure your pallets are compatible with your 3PL’s equipment. Discuss with your 3PL if you have concerns.

Load Capacity

Load capacity is the maximum weight a pallet can hold. Make sure your pallets can handle the expected load. Amazon has a total weight limit of 1,500lbs per pallet. If your cargo is heavy, use sturdy, high-quality pallets like hardwood (oak and pine). Lightweight or damaged pallets might not be durable enough once fully loaded.

Durability

Durability refers to a pallet's ability to withstand rough handling through various shipping stages. Check for signs of wear and tear, especially from forklift blades. If the damage is extensive, replace with new or higher-grade pallets. If the pallet is for single use, durability may be less crucial. Volume and cargo weight are also considerations. For high volumes or heavy objects, use premium pallets for the best value.

Pallet Stiffness

Pallet stiffness measures how much a pallet bends under load over time. If the pallet collapses, boxes may bulge, causing load instability and product damage. Ensure pallets hold their shape when loaded. Heavier cargos require higher stiffness ratings. Thicker deck boards generally mean better stiffness, though they cost more. The benefits, including reduced inventory shrinkage, outweigh the costs.

Pro tip: Investing in stiffer pallets ensures maximum protection. Using sturdy boxes is equally important. Adjust the flute size and cardboard grade to increase box compression strength.

Budget

Determine your budget for pallets and which type provides the best value. Due to recent cost increases, buying pallets at today's prices requires consideration. High-quality pallets are less likely to break, ensuring fewer additional costs. Poor-quality pallets can lead to inventory breakage and extra fees, making them more expensive in the long run.

Related: Inventory and Logistics to Stay Profitable in 2022

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