How to Prepare a Pallet for Shipping in Australia: Stacking, Wrapping and Labelling Checklist

A badly packed pallet is like a Jenga tower on the back of a truck. It looks fine at the dock. Then it meets the Hume Highway.

Here is how to prepare a pallet for shipping in Australia: use a sound pallet, pack goods into cartons, stack heavy cartons at the bottom in straight columns, keep everything inside the pallet edges, wrap and strap the load to the pallet itself, and put clear labels on the sides. Then measure and weigh the finished pallet before you book.

At NLM, we book pallet freight across many carriers every week. This guide is the checklist we wish every shipper had before that happened. Let's walk through it, step by step.

What Is the Australian Standard Pallet?

The Australian standard pallet is a square timber pallet that measures 1165 x 1165 mm. It is about 150 mm high and is usually made from hardwood. Its size is different from the European (1200 x 800 mm) and US (1200 x 1000 mm) pallets.

Why the odd size? Two Australian pallets side by side measure 2330 mm. That fits neatly across the roughly 2.4 m width of Australian trucks and containers, with a little room to spare.

Good to know: pallet specs and carrier limits vary. The numbers above are typical, not universal. Your quote is the final word on the size and weight your carrier will accept.

Step 1: Choose the Right Pallet

Start with a pallet that is strong, dry and in one piece. Cracked boards, missing blocks or popped nails are a no. A weak pallet can fail on the forklift, and that is the worst time to find out.

CHEP, Loscam or plain pallet?

In Australia you will see three main kinds of pallet:

• CHEP pallets (blue): hired from a pool, not owned. You need a CHEP account, and the pallet must be tracked back.
• Loscam pallets (red): also a hire pool, with its own account system.
• Plain or "white" pallets: you own them outright. No account, no return, no tracking.

Here is the catch. If you send goods on a hire pallet and the receiver has no account, the pallet may need to be unloaded and handed back. Or you may be charged for it. For one-off or general freight, a plain pallet is usually the simplest choice.

Shipping overseas? Think ISPM 15

For export, wooden pallets must meet ISPM 15. This is the global standard for wood packaging. The wood must be treated, often by heating it to at least 56°C for 30 minutes. It must also carry the official stamp. In Australia, this is run through the Department of Agriculture's Australian Wood Packaging Certification Scheme. ISPM 15 does not apply to domestic freight. If your pallet is heading offshore, see our international courier services.

Step 2: Pack Your Goods Into Cartons First

Loose items on a pallet are troublesome. Pack goods into sturdy, uniform cartons first. Same-size boxes stack flat, spread weight evenly and hold each other in place.

• Fill empty space inside each carton so it cannot crush.
• Seal every carton with good tape.
• Put a board or slip sheet on the pallet deck first, so small items cannot drop through the gaps.

Step 3: Stack for Stability (Your Pallet Stacking Guide)

A good pallet stacking guide comes down to one idea: build a solid, flat-topped cube. Here is how.

1. Heaviest on the bottom. Heavy cartons go down low. Light and fragile cartons go on top.
2. Stack in straight columns. Line boxes up corner to corner. Column stacking uses the strength of each box's corners. Brick (interlocked) stacking grips better, but it lowers crush strength. So for heavy cartons, use columns and let the wrap do the holding.
3. No overhang. Keep every carton inside the pallet edges. Boxes that hang over get crushed, catch on forks and can be refused.
4. No pyramids. A pointy top cannot take another pallet. That can make it "non-stackable" and cost you more.
5. Keep the top flat and level. A flat top means your pallet can be stacked on, which usually keeps the price down.
6. Watch the height. Many carriers cap total height at around 1.8 m, pallet included. Some services are lower.

A quick test: stand back and look. Does it look like a neat box? Or a wedding cake? You want the box.

Step 4: How to Wrap a Pallet (and Strap It)

The short answer on how to wrap a pallet: tuck the stretch wrap into the pallet base, wind it tight from the bottom up with overlapping layers, add extra layers at the base and top, and finish over the top of the load. One thin layer is not enough.

Stretch wrap, step by step

1. Tie the wrap end to a corner of the pallet itself, not just the boxes.
2. Do three or four tight laps around the pallet base. This locks the load to the pallet.
3. Work up the load, overlapping each lap by about half.
4. Pull the film tight as you go. Loose wrap lets the load sway.
5. Add extra laps at the top, then fold the film over the top edge.
6. Work back down to the base and finish with a few more laps.

Add straps and edge boards

Wrap holds the cartons together. Straps hold the cartons to the pallet. For heavy or tall loads, use both. Run at least two straps each way, under the pallet top boards, not just around the boxes.

Put cardboard edge boards (corner protectors) on the four vertical corners before strapping. They stop the straps cutting into cartons and add stiffness to the whole load. A top sheet of cardboard helps too.

Stretch wrap and shrink wrap are not the same. Stretch wrap clings by tension and is what most shippers use. Shrink wrap is shrunk on with heat. Either works if the load is tight.

Step 5: How to Label a Pallet for Freight

Labels tell every depot and driver where your pallet is going and how to handle it. Get them wrong and your freight can end up in the wrong state.

• Stick labels on the sides, not the top. The top gets covered when pallets stack.
• Label at least two sides. If one gets torn, the other still reads.
• Match the consignment note. The label, the booking and the paperwork must show the same details.
• Mark special handling. Use "Fragile", "This Way Up" or "Do Not Stack" labels where needed. Non-stackable pallets often need labels or cones, and usually cost more.
• Declare dangerous goods. If anything is a dangerous good, it must be declared and labelled under the Australian Dangerous Goods (ADG) Code. Never hide it inside general freight.

Step 6: Measure and Weigh Before You Book

This is where most surprise charges come from. Your quote is based on the size and weight you enter. If the carrier measures something bigger or heavier, you get re-quoted.

• Measure the finished pallet, after wrapping. Include the pallet itself.
• Measure at the widest point on each side, not the pallet base.
• Weigh the whole thing, pallet included.
• Round up, not down.

Freight is often charged on cubic weight, not just dead weight. A light but tall pallet can cost more than you expect. Once you have real numbers, get a quote so the price you see is the price you pay.

Common Pallet Mistakes That Lead to Surcharges

Your Legal Side: Chain of Responsibility

Here is something many shippers do not know. In Australia, the person who packs a load has legal duties too, not just the driver.

Under the Heavy Vehicle National Law, the Chain of Responsibility means everyone who packs, loads or consigns freight shares responsibility for safe loads. The National Transport Commission's Load Restraint Guide 2018 sets out the safety principles. It says that if you are involved in packing or loading, you are responsible for meeting load restraint laws. Note that WA and the NT still reference the 2004 edition.

A pallet that is stacked, wrapped and labelled well is not just cheaper to ship. It is part of doing the right thing by the drivers and people handling it. This is general information, not legal advice. Check the current rules for your state.

Your Printable Pallet Shipping Checklist

When Should You Ship on a Pallet?

Not every shipment needs a pallet. As a rough guide, carriers tend to want a pallet once freight gets heavy or bulky. For example, TNT Australia says items over 70 kg, or larger than 2.4 x 1.2 x 1.5 m, should go on a pallet. Other carriers set their own limits.

If you are sending lots of cartons to one place, a pallet is often safer and simpler. For smaller jobs, our domestic courier services may suit you better. Moving large volumes on a regular basis? Look at our bulk shipping services.

When your pallet is ready, NLM compares rates across our network of carriers to find the right fit for your freight. See how our pallet shipping services work.

Frequently Asked Questions

How do I prepare a pallet for shipping?

Pack goods in cartons, stack heavy ones low in straight columns, keep them inside the edges, wrap and strap them to the pallet, label two sides, then measure and weigh it.

What size is a standard pallet in Australia?

The Australian standard pallet is 1165 x 1165 mm and about 150 mm high. It is square, unlike European and US pallets, which are rectangular.

How high can I stack a pallet for freight?

Many carriers cap total height at around 1.8 m, pallet included. Some express services are lower, so check the limit on your quote before you stack.

Do I need to wrap a pallet before shipping?

Yes. Most carriers expect pallets to be stretch wrapped or strapped, with the wrap locked to the pallet base. For heavy loads, use both wrap and straps.

Where should labels go on a pallet?

Put labels on the sides, not the top, and label at least two sides. Make sure the details match your booking and consignment note exactly.

Worried about damage in transit? You can also add freight insurance for extra peace of mind.

Final Thoughts

Knowing how to prepare a pallet for shipping saves you money, time and stress. Build a neat cube. Lock it to the pallet. Label it clearly. Measure it honestly. Do that, and your freight travels like it should.