Packaging Guide

Use standard 48×40″ pallets in good condition. All deck boards should be intact with no cracks or missing pieces.

Never use broken, cracked, or water-damaged pallets. Carriers can reject freight on damaged pallets.

Stack cartons flush with or inside the pallet edges. Use edge protectors if boxes come right to the edge.

Never let cartons overhang the pallet. Overhang gets crushed during loading and causes damage claims.

Keep total height (pallet + cargo) under 90 inches (7.5 feet). This allows safe stacking in the trailer.

Overheight pallets can't be double-stacked, may be refused by carriers, and are prone to toppling.

Wrap the entire pallet — cartons AND the pallet deck — with at least 3 layers of quality stretch wrap.

Wrapping only the boxes (not the pallet) lets them slide off during transit. This is the #1 cause of freight damage.

Use polypropylene or steel banding to secure top-heavy, round, or irregularly shaped items to the pallet.

Relying on shrink wrap alone for heavy items. Wrap + band is the winning combo.

Place the heaviest items on the bottom. Fill gaps with dunnage, foam, or packing paper to prevent shifting.

Stacking heavy boxes on top of light ones. The bottom layer crushes and the whole pallet becomes unstable.

Place the heaviest items on the bottom. Fill gaps with dunnage, foam, or packing paper to prevent shifting.

Stacking heavy boxes on top of light ones. The bottom layer crushes and the whole pallet becomes unstable.

Choose boxes that fit the item snugly with 2–3 inches of padding on all sides. Fill empty space with packing material.

Oversized boxes with items rattling around inside. The item will find the weakest wall and punch through it.

Place the item in a snug inner box with padding, then place that box inside a larger outer box with more padding.

Single-boxing electronics, glass, or ceramics with just a layer of bubble wrap. It won't survive USPS.

Use 2-inch packing tape on all seams — top, bottom, and the center seam. The H-tape method is best.

Duct tape, masking tape, or a single strip across the top. These fail in humid conditions and during transit.