Palletizing international air freight can improve transportation efficiency and protect cargo, but it requires adherence to regulations to avoid damage, airline rejection, or additional fees due to improper handling.
In this article, Weefreight will share key considerations, covering aspects such as pallet selection, cargo placement, and securing methods. We hope this will be helpful.
- Pallet Selection and Compliance
Pallet Compatibility
Preferably, choose a pallet size that complies with airline standards. Common air freight pallet specifications are 120cm × 80cm (European standard) or 120cm × 100cm (suitable for some wide-body aircraft). Please confirm airline requirements in advance (they may vary between different airlines and aircraft models).
Pallet height must be strictly controlled: Generally, the total height of the pallet and cargo should not exceed 1.6-1.8 meters (subject to airline regulations; narrow-body aircraft have stricter restrictions, which may not exceed 1.5 meters) to avoid exceeding the cabin loading space. Pallet Materials and Compliance Requirements
Wooden pallets must comply with the ISPM 15 international standard, requiring heat treatment (HT) or methyl bromide fumigation (MB). The IPPC mark (including the treatment code, country/region code, and treatment agency code) must be marked on the pallet. Failure to do so may result in customs detention or return in the destination country.
Plastic pallets: Choose strong, wear-resistant food-grade or industrial-grade plastics (such as PP/PE) to prevent cargo from being scattered due to pallet damage. Some airlines have load-bearing requirements for plastic pallets (usually no more than 1000kg per pallet), so please confirm this in advance.
Metal pallets: While they offer strong load-bearing capacity, they are heavier (increasing the chargeable weight). They are only recommended for heavy cargo (such as mechanical parts) and must be free of sharp edges to avoid scratching the cabin or other cargo.
Pallet Condition Inspection
Pallets must be intact: free of cracks, deformation, or exposed nails. The pallet’s bottom support legs must be secure (to prevent tipping over when stacked), and the pallet surface must be clean (free of oil, water stains, contaminants, and especially hazardous materials).
II. Cargo Placement Guidelines on Pallets
“Heavy at the bottom, light at the top, large at the bottom, small at the top” Principle
Heavy cargo (such as metal products and equipment) should be placed at the bottom of the pallet, while light cargo (such as textiles and cartons) should be placed at the top to prevent the upper layers from crushing the lower layers. Large cargo should be placed at the bottom first, with small cargo filling gaps to ensure a stable center of gravity (a shift in the center of gravity can easily cause the pallet to tilt or collapse).
“White Space” Requirements Between Cargo and Pallet Edges
Cargo must be completely within the pallet’s perimeter, with the top cargo no more than 5cm from the pallet edge, and the bottom cargo must not extend beyond the pallet edge (to prevent cargo from sliding off the pallet during loading and unloading, or incurring additional charges from airlines for exceeding dimensions).
Stack tightly to avoid hollow spaces
Similar items should be stacked neatly as much as possible. Carton-type items can be staggered (e.g., horizontally on the first layer and vertically on the second) to minimize gaps. Irregularly shaped items (e.g., tubular or special-shaped items) should be filled with fillers (e.g., bubble wrap or foam board) to prevent shifting during transport.
Weight Limit for Single Items
If multiple items are placed on a pallet, the recommended weight for each item should not exceed 80kg (non-wide-body aircraft) or 100kg (wide-body aircraft). If this exceeds the weight limit, please contact the airline in advance (some airlines require overweight items to be palletized separately or with corner clips).
III. Cargo Securing and Reinforcement Methods
Wrapping with Stretch Film – Basic Securing
Use PE stretch film to wrap the items in a spiral upwards, starting from the bottom of the pallet. Wrap at least 3-5 layers upwards, covering the top surface of the items and wrapping down to the bottom of the pallet (forming a “closed loop”). Ensure the items fit tightly to the pallet to prevent them from falling apart during transport.
Strapping Reinforcement – For Heavy/Large Shipments
For shipments weighing over 500kg or larger, use PP strapping (width ≥ 15mm) in a cross-stretching pattern (at least two horizontal and two vertical strips). The strapping should be tightened and secured to the edge of the pallet to prevent slippage. If necessary, place cushioning pads (such as cardboard) where the strapping meets the shipment to prevent damage.
Pallets/Corner Guards – Protecting Fragile Items
For shipments in cardboard or wooden boxes or with fragile corners (such as furniture or equipment), plastic corner guards or metal pallets should be installed on the top, bottom, and edges to prevent damage from forklift collisions during loading and unloading. If the shipment is over 1.2 meters tall, it is recommended to install “boarding” (wooden or plastic) around the pallet to enhance overall stability.
Additional Securing of Special Cargo
Liquid cargo (e.g., drummed chemicals): Place a leak-proof pallet (with grooves on the bottom) on the pallet and secure the drum with straps (at least two straps per drum) to prevent spillage.
Precision instruments/electronic equipment: In addition to wrapping film and packing tape, wrap the cargo with foam padding and then seal it in a wooden box or pallet box (the pallet box and pallet must be secured with screws) to ensure shock and drop protection.
IV. Labeling and Information
“Shipping Label” on the Pallet
Affix a clear shipping label to the side of the pallet (at least two opposite sides) containing the waybill number, destination airport code, consignor/consignee name, and number/weight of packages. If the cargo is hazardous goods, a hazardous goods label (e.g., UN number, hazardous goods category) must be affixed in accordance with the IATA Dangerous Goods Regulations and marked “Palletized.”
Center of Gravity Marking – For Overweight/Unevenly Loaded Cargo
If the center of gravity of a palletized cargo is offset (e.g., if the weight on one side exceeds 60%), a “Center of Gravity” marking (with an arrow pointing to the center of gravity) should be marked on the pallet surface to remind loaders to pay attention to the direction of forklift operation and avoid tipping the pallet.
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