Blog · Pallet Strategy
Complete Guide to Pallet Sizes
This is your one-stop reference for pallet footprints. Bookmark it to compare global standards, understand why sizes vary, master the five-step selection workflow, and get fast answers to the questions operators ask every week.
1. What Do We Mean by “Pallet Size”?
Pallet size refers to the outside length × width. Height is often bundled in, yet real-world planning needs more than just footprint. Pay attention to:
- Material (wood, plastic, corrugated, metal) because sanitation, repair, and unit cost all depend on it.
- Structure (stringer vs block, 2-way vs 4-way, full-perimeter vs open bottom) for compatibility with forklifts and conveyors.
- Undercarriage & lead board spacing to confirm pallet jack entry and automated system fit.
- Load ratings – static, dynamic, and racking limits can differ dramatically.
- Compliance such as ISPM 15 heat treatment for export. Plastic pallets avoid those checks but cost more.
2. Global Pallet Size Cheat Sheet (mm ↔ inch)
| Region / System | Common Name | Size (mm) | Size (inches, approx.) | Typical Height | Usage Notes |
|---|---|---|---|---|---|
| North America (GMA) | 48 × 40 | 1219 × 1016 | 48 × 40 | 140–165 | Mainstream in grocery and retail DCs |
| Europe (EPAL 1 / EUR 1) | Euro pallet | 1200 × 800 × 144 | 47.2 × 31.5 × 5.7 | 144 | Standard pool asset across EU & UK |
| Europe (EPAL 2 / 3) | Euro wide | 1200 × 1000 / 1000 × 1200 | 47.2 × 39.4 / 39.4 × 47.2 | ≈144 | Industrial, heavy equipment, chemicals |
| Australia (AS) | Aussie pallet | 1165 × 1165 | 45.9 × 45.9 | ≈150 | Tailored to Australian racking and trucks |
| Asia-Pacific | Asia square | 1100 × 1100 | 43.3 × 43.3 | 140–160 | High cube utilization for ocean freight |
| North America | 42 × 42 | 1067 × 1067 | 42 × 42 | 140–160 | Beverage and chemical shuttle pallet |
| Retail / Display | EPAL 6 / 7 | 800 × 600 variants | 31.5 × 23.6 | 120–144 | European quarter / half pallet for promo |
Tip: use mm = inch × 25.4 and inch = mm ÷ 25.4 when switching between units. Heights shift by material; EPAL stays at 144 mm while standard US wood pallets sit between 5.5–6.5 in (140–165 mm).
3. Why So Many Pallet Sizes?
- Vehicle & warehousing standards differ. North America optimizes for 53 ft trailers and rack spacing; Europe designs around the Euro block pallet; Australia and Asia lock in their own standards.
- Container optimization matters. Square pallets (1100 × 1100, 1000 × 1200) land tighter cube inside 20/40 ft boxes.
- Industry-specific needs. Beverage, pharma, and electronics often demand square pallets for automation; retail cares about pool compatibility and front-of-store display sizes.
- Regulation & compliance. Wood exports require ISPM 15 (HT) stamps; plastic pallets skip fumigation but change your cost model.
4. Five-Step Pallet Selection Workflow
Goal: choose the pallet that fills space, moves safely, and keeps cost-per-trip in check.
Step 1 — Match product to pallet
- Record carton length, width, height, and allowed stack patterns.
- Calculate surface utilization = (cartons per layer × carton footprint) ÷ pallet footprint.
Step 2 — Confirm transportation lanes
- Domestic U.S. flows lean on 48 × 40. EU lanes pick 1200 × 800 or 1200 × 1000. Ocean-heavy mixes favor 1100 × 1100.
- Pool networks (CHEP, EPAL, LPR, IPP) dictate specific pallet specs—follow their playbook.
Step 3 — Validate facility & equipment fit
- Check rack beam spacing, forklift tine width, pallet jack lift height, and conveyor tolerances.
- Automated storage, cold chain, or cleanroom sites often need closed decks or higher stiffness.
Step 4 — Pick material & structure
- Wood pallets are low cost and repairable but need HT for export.
- Plastic pallets stay dimensionally stable, clean easily, and skip fumigation.
- Choose bottom structure (full perimeter vs nine-leg) based on handling cycle and racking.
Step 5 — Confirm load ratings
- Separate static, dynamic, and racking loads. Exceeding racking limits is the fastest route to failure.
- For shuttle systems or push-back racks, specify reinforcements or steel stringers upfront.
5. Utilization Example
- Carton size: 400 × 300 mm
- Euro pallet (1200 × 800): 3 × 2 pattern = 6 cartons → utilization = (6 × 0.4 × 0.3) ÷ (1.2 × 0.8) = 75%.
- GMA pallet (1219 × 1016): 3 × 3 pattern = 9 cartons → utilization = (9 × 0.4 × 0.3) ÷ (1.219 × 1.016) ≈ 87%.
- Takeaway: U.S. footprint wins on fill rate, yet Euro pallets slot into shared pool networks. Pick what best balances transport, reverse logistics, and return loops.
Aim for ≥80% surface utilization. If you can’t reach it, revisit carton size or pallet choice.
6. How Pallet Height & Fork Entry Change the Game
- Pallet height affects trailer cube, rack clear height, and stacking stability.
- EPAL is locked at 144 mm; most wood or plastic GMA pallets sit between 140–165 mm.
- Always verify underside clearance versus forklift tine height plus safety margin.
7. Vehicle & Container Fit Checklist
- Pick the pallet first, then tune carton count. Total stack height must stay under trailer or container inside height.
- Map the footprint. Simulate pallets within the trailer or container to avoid door frame interference and tie-down obstacles.
- Secure the load. Use straps, stretch wrap, and void fillers; avoid overhang where possible.
- Remember regional truck sizes. A pallet that rides well in one market might be awkward elsewhere, so involve your 3PL early.
8. Common Mistakes to Avoid
- Starting with the pallet you already own instead of recalculating from carton + lane data.
- Using static load ratings on racks—pallets collapse more easily than you think.
- Allowing carton overhang to “cheat” cube; it raises damage, wrap, and safety risks.
- Ignoring bottom deck style so pallets sag or fall through rack beams.
- Forgetting environmental requirements—cold storage and food processors often reject the wrong material.
9. Related Reading
- Need Euro-specific specs? Read Euro Pallet Size.
- Comparing materials? Check Plastic Pallets Guide and Wooden Pallets Guide.
- Want quick dimension lookups? Open the Pallet Dimensions cheat sheet.
10. FAQ
What is the standard U.S. pallet size?
The primary footprint is 48 × 40 in (1219 × 1016 mm) with four-way entry, often called the GMA pallet.
How big is a Euro pallet?
The EPAL 1 pallet measures 1200 × 800 × 144 mm. Other Euro formats include 1200 × 1000, 1000 × 1200, and 800 × 600 mm.
Is pallet height standardized?
No. EPAL pallets stay at 144 mm, while most U.S. wooden and plastic pallets range from 140 to 165 mm. Always request the manufacturer datasheet.
What matters most when choosing a pallet?
Start with carton footprint and utilization, confirm lane standards, then validate equipment fit and load ratings.
Do plastic and wooden pallets share the same dimensions?
They can be built to identical footprints, but the underside geometry, deck thickness, and load ratings differ—measure before you swap.
Closing Thoughts
Pallets may be the smallest line item on your logistics budget, yet they connect warehouse flow, transport, and customer delivery. Before every buy cycle, revisit the chain: carton → pallet → equipment → route. Keep this guide handy, share it with your ops partners, and reach out if you need help modeling a specific scenario.