Palletizing for international air freight can improve transportation efficiency and protect cargo, but it requires compliance with regulations to avoid damage, airline rejection, and additional fees due to improper handling.
In this article, Weefreight will share some 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 sizes are 120cm x 80cm (European standard) or 120cm x 100cm (suitable for some wide-body aircraft). Please confirm airline requirements in advance (they may vary between 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 (specific restrictions apply to airline regulations; narrow-body aircraft have stricter restrictions, possibly no more than 1.5 meters) to avoid exceeding the cabin loading space.
Pallet Materials and Compliance Requirements
Wooden pallets: They must comply with the ISPM 15 international standard and must be heat-treated (HT) or fumigated with methyl bromide (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 weight requirements for plastic pallets (usually no more than 1000kg per pallet), so please confirm this in advance.
Metal pallets: While strong, they are heavy (increasing the chargeable weight) and are recommended only for heavy cargo (such as machinery parts). They must be free of sharp edges to avoid scratching the cabin or other cargo.
Pallet Condition Inspection
The pallet must be intact: free of cracks, deformation, or exposed nails. The bottom legs must be secure to prevent tipping over during stacking, and the 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” principle
Heavy cargo (such as metal products and equipment) should be placed on the bottom of the pallet, while light cargo (such as textiles and cartons) should be placed on the top to prevent the upper layers from damaging the lower layers. Larger cargo should be placed on the bottom layer, with smaller 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.
Requirements for “Blank Space” Between Cargo and Pallet Edges
Cargo must be completely within the pallet, 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 the airline for exceeding dimensions).
Stacking Compactly to Avoid “Hollow Spaces”
Similar cargo should be stacked neatly as much as possible. Carton-type cargo can be stacked in a staggered manner (e.g., horizontally on the first layer and vertically on the second layer) to minimize gaps. Irregularly shaped cargo (e.g., tubular or special-shaped items) should be filled with filler (e.g., bubble wrap or foam board) to prevent shifting during transport.
Weight Limit for Single Cargo Pieces
If multiple pieces are placed on a pallet, the recommended weight for each piece is 80kg (non-wide-body aircraft) or 100kg (wide-body aircraft). If the weight exceeds this limit, please contact the airline in advance (some airlines require overweight cargo to be palletized separately or with corners).
- Cargo Securing and Reinforcement Methods
Wrapping with Stretch Film – Basic Securing
Starting from the bottom of the pallet, wrap the cargo in a spiral upwards, using at least 3-5 layers of PE stretch film. The top layer should cover the cargo surface and then wrap down to the bottom of the pallet (forming a “closed loop”). This ensures a tight fit between the cargo and the pallet to prevent it from falling apart during transport.
Strapping with Strapping – For Heavy/Large Cargo
For cargo weighing over 500kg or larger, use PP strapping (width ≥ 15mm) in a cross-strap arrangement (at least two horizontal and two vertical strips). The strapping should be tightened and secured to the edge of the pallet to prevent slipping. If necessary, place cushioning pads (such as cardboard) where the strapping tape contacts the cargo to prevent damage.
Pallets/Corner Guards – Protecting Fragile Parts
If the cargo is in cardboard or wooden boxes or has delicate corners (such as furniture or equipment), plastic corner guards or metal pallets should be installed on the top, bottom, and edges of the cargo to prevent damage from forklift collisions during loading and unloading. If the cargo is over 1.2 meters tall, it is recommended to install “boards” (wooden or plastic) around the pallet to enhance overall stability.
Additional Securing for Special Cargo
Liquid cargo (such as 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 tipping and leaks.
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
External Pallet “Shipping Labels”
Affix clear shipping labels to the sides of the pallet (at least two opposite sides) containing the following: waybill number, destination airport code, consignor/consignee name, and number/weight of cargo. If the cargo is hazardous goods, a hazardous goods label (such as the UN number and hazardous goods category) must be affixed in accordance with the IATA Dangerous Goods Regulations, and the words “Pallet Loaded” must be marked.
Center of Gravity Marking – For Overweight/Unevenly Loaded Cargo
If the center of gravity of the cargo on the pallet is offset (e.g., the weight on one side exceeds 60%), a “Center of Gravity” marking (with an arrow pointing to the center of gravity) must be marked on the pallet surface to remind loading and unloading personnel to pay attention to the direction of forklift operation and avoid tipping the pallet.
Special Handling Labels
If the cargo requires “upward loading,” “moisture-proof,” or “fragile,” appropriate handling labels (such as “THIS SIDE UP” or “FRAGILE”) must be affixed in a conspicuous location on the pallet. The label must be clear and durable (avoiding being covered or worn by wrapping film).
V. Advance Communication with the Airlines/Freight Forwarders
Confirm the Airlines’ Pallet Restrictions
Different airlines may have different pallet requirements (for example, some budget airlines have a pallet weight limit of 800kg, while wide-body aircraft may have a limit of 1500kg). You should confirm with your freight forwarder or airline in advance regarding the pallet’s dimensions, maximum weight, and whether you need to declare “palletized cargo” in advance (some airlines require this to be noted during booking).
Special Declaration for Oversized/Overweight Pallets
If the total weight of the pallet and cargo exceeds 250kg (narrow-body aircraft) or 1000kg (wide-body aircraft), or if the pallet is longer than 3 meters, you must apply for “oversized cargo handling” in advance. Provide the pallet’s detailed dimensions (length × width × height) and weight, and confirm whether the airline has suitable aircraft (such as wide-body aircraft like the B747 and A330). You may also be required to pay an “oversized cargo surcharge.”
Confirming the Chargeable Weight of Palletized Cargo
The weight of the pallet itself is included in the total chargeable weight (approximately 15-20kg per wooden pallet, 5-10kg per plastic pallet). Please confirm with the freight forwarder in advance whether the pallet weight is included in the quote to avoid disputes during settlement.
Summary
The core of palletizing for international air freight is “safety, stability, compliance, and efficiency.” This requires protecting cargo through appropriate pallet selection, cargo placement, and securing methods, while also complying with airline operating procedures and customs requirements. Advance communication with the freight forwarder, strict inspection of the pallet and cargo condition, and clear labeling can effectively avoid unexpected transportation issues and ensure smooth customs clearance and delivery.
So, how can you avoid cargo damage during palletizing for international air freight?
Cargo damage during palletizing for international air freight often stems from issues such as improper pallet selection, improper cargo placement, insecure securing, or improper operation. To effectively prevent these issues, targeted measures must be taken from multiple perspectives, including pallet compatibility, cargo placement logic, securing and reinforcement methods, special cargo protection, and standardized operating procedures. Specifically, the following key points can be followed:
First, Choose the Right Pallet: Eliminate Potential Risks from the “Basic Carrier”
The pallet is the primary support for the cargo. If the pallet itself is not compliant or mismatched with the cargo, subsequent handling can easily lead to cargo damage, even with standardized procedures. Three key points require attention:
The load capacity must be perfectly aligned with the cargo weight.
The pallet’s rated load capacity must be greater than the total cargo weight plus the pallet’s own weight (it’s recommended to leave at least a 20% margin) to prevent deformation or breakage due to insufficient load capacity. (For example, for a 1-ton load, choose a pallet rated at 1.2 tons or more, not just 1 ton.)
If the cargo is a heavy single piece (such as a 500kg mechanical part), choose a reinforced pallet (a wooden pallet with metal bottom legs and a panel thickness of 1.8cm or greater, or a high-density plastic pallet) to prevent partial collapse due to excessive force.
Size and Cargo: “Adapt to No Waste”
Pallet size must match the overall volume of the cargo: If the cargo consists of multiple small cartons (e.g., 100 30cm x 20cm x 20cm cartons), prioritize a pallet size that allows the cargo to “just fill the pallet with no noticeable gaps” (e.g., a 120cm x 80cm pallet can neatly accommodate 16 cartons). This prevents the cargo from wobbling and leaving gaps on the pallet due to an oversized pallet. For extra-long items (e.g., 2-meter-long pipes), choose an extended pallet (or custom pallet) to ensure at least 10cm of pallet support at both ends. (Cargo overhanging more than 30% is prohibited, as this can easily cause breakage during loading and unloading due to an unstable center of gravity.)
Thoroughly Check Pallets for Hidden Defects
Inspect pallets before use: Wooden pallets should be free of loose nails, burrs, or cracks (exposed nails can easily snag cargo packaging, and cracks can cause partial sinking of cargo); plastic pallets should be inspected for signs of aging, brittleness, and edge damage (plastic pallets exposed to sunlight are prone to cracking and need to be replaced); metal pallets should be cleaned of surface rust and sharp edges (rust can contaminate cargo, and sharp edges can scratch packaging).
II. Cargo Placement: Stack according to “physical stability”
The way cargo is placed on the pallet directly affects whether it will be damaged during transportation due to shaking, squeezing, or shifting of the center of gravity. The key principles are “low center of gravity, even load distribution, and no gaps”:
“Heavy goods at the bottom, light goods at the top, large goods at the bottom, small goods at the top” + “centered center of gravity”
Heavy, hard goods (such as metal boxes or solid wooden crates) must be placed on the bottom layer, while light, soft goods (such as textiles and foam packaging) must be placed on the top layer. The weight of the top layer should be ≤ 1/3 of the weight of the bottom layer (e.g., if a 50kg cardboard box is placed on the bottom layer, a maximum of 15kg boxes can be placed on the top layer) to avoid crushing the bottom layer.
Cargo should be stacked “closer to the center of the pallet”: If the cargo is irregularly shaped (e.g., heavier on the left side and lighter on the right), adjust the position so that the center of gravity is centered on the pallet (use a tape measure to measure the intersection of the pallet’s diagonals to ensure the deviation between the overall center of gravity and the intersection is ≤ 10cm) to prevent the pallet from tipping over during transport.
“Compact and Gaps-Free” + “Avoid Direct Squeezing”
Similar goods should be stacked in an “interlaced” manner (e.g., horizontally on the first layer, vertically on the second). Fill gaps with filler material (e.g., bubble wrap, cardboard). This is especially true for cardboard-based goods; gaps can cause corners to break or become deformed due to shaking during transport.
Fragile items (e.g., glassware, electronic screens) should be “separated”: they should not come into direct contact with hard or heavy goods. Fragile items can be wrapped with foam edge guards or a layer of shock-absorbing cushioning (e.g., EVA padding) can be placed on the pallet before placing the fragile items.
Avoid “top-heavy” stacking by avoiding excessive height.
The total height of the pallet and cargo must strictly comply with airline requirements (≤ 1.5 meters for narrow-body aircraft, ≤ 1.8 meters for wide-body aircraft), and the height must be ≤ 1.5 times the width (e.g., a 1-meter-wide pallet should not exceed a total height of 1.5 meters). Otherwise, stacking can cause the cargo to topple over due to a “top-heavy” stacking.
If the total height of the cargo is higher (e.g., 1.6 meters), temporary barriers (wooden or plastic panels at least 1/2 the height of the cargo) must be installed around the pallet to limit lateral movement.
Third, Securement: “Multi-layered Protection” Keeps Cargo “Immovable”
Once stacked, if cargo is not securely secured, it can easily become scattered or collided during transportation (e.g., due to forklift transfers or aircraft cabin turbulence). Choose a combination of “basic securing + reinforced securing” depending on the cargo type:
Basic securing: Stretch film for airtightness
Use PE stretch film (thickness ≥ 0.02mm) in a spiral wrap from the bottom of the pallet: First wrap it around the bottom of the pallet twice (to secure the pallet to the cargo base), then wrap upwards, overlapping by 1/3 of the pallet width with each wrap. The top should cover the cargo surface and then wrap back down to the bottom of the pallet (forming a “closed loop”). A total of 5 layers should be used (8-10 layers are required for heavy cargo).
When wrapping, keep the film tight (ideally enough to slightly indent the cargo packaging) to avoid it being too loose and failing to secure the cargo. If there are vulnerable areas on the cargo surface (such as the carton seal), apply tape to reinforce the area before wrapping with the stretch film.
Strengthened Securement: Strapping Tape for Cross-Loading and Corner Protectors for Collision Prevention
For cargo weighing 300kg or more or 1m³ or larger, cross-strap PP strapping tape (width ≥15mm, thickness ≥0.8mm) must be used: at least two horizontal straps (along the width of the pallet, bypassing the bottom support legs) and at least two longitudinal straps (along the length of the pallet). The strapping points must be located on the load-bearing edges of the pallet to avoid tying the cargo and causing localized damage.
Add Cushioning Where Strapping Tape Contacts the Cargo: For soft packaging such as cardboard or plastic boxes, place cardboard or plastic corner protectors underneath the strapping tape to prevent the packaging from being crushed when tightened (cardboard cartons are particularly susceptible to “fracture” from the tension of the strapping tape).
Extra-high/extra-wide cargo requires “additional reinforcement bars”: If the cargo is taller than 1.2 meters or slightly wider than the pallet (≤5 cm), “horizontally install wooden reinforcement bars” on the top of the pallet (screwed to both sides of the pallet). Then, use straps to secure the cargo to the reinforcement bars to prevent up and down movement.
Special cargo: “Customized securing” to prevent extreme damage.
Liquid cargo (such as barreled chemicals): First, place a “leakproof pallet” (a plastic pallet with grooves on the bottom to prevent leakage) on the pallet, then secure the barrels with “tie straps”(Place rubber pads between barrels to prevent collisions). Finally, wrap the entire barrel with stretch film and strapping tape (the strapping should go around the middle of the barrel to avoid tightening the barrel opening and causing leaks).
Precision instruments/electronic equipment: In addition to standard wrapping and packaging, wrap the entire equipment with foam board (thickness ≥ 5cm). Then, use a pallet box (wooden or metal frame) to completely enclose the goods and pallet (the pallet box and pallet are fixed with screws). Fill the gaps inside the box with pearl cotton to provide dual protection against shock and crush.
IV. Operational Process: Avoid collisions throughout the entire process, from loading and unloading to transportation.
Many cargo damages are not caused by “fixed issues” but rather by “bumps during handling” (such as forklifts hitting pallets or crushing during stacking). Clear labeling and standardized operations are necessary to reduce human error:
Post clear “operational signs” to provide operators with clear instructions.
Apply clear labels on two opposing sides of the pallet:
Basic markings: Waybill number, consignor/consignee, gross weight of cargo/ Number of pieces;
Operational signs: “FRAGILE,” “THIS SIDE UP,” “Center of Gravity” (marked with an arrow), “DO NOT STACK” (if the goods cannot be stacked);
Signs must be wear-resistant (covered with waterproof tape) and not completely obscured by the wrapping film (a separate sign can be applied to the outside of the wrapping film).
Standardize “forklift operation” to avoid “rough loading and unloading”
When picking up a pallet with a forklift, ensure that the forklift arm fully extends under the pallet (forklift arm length ≥ 2/3 of the pallet depth). Avoid tilting the pallet by only gripping the front end. When lifting a pallet, lift it slowly (no more than 1 meter to avoid shaking), and reduce speed when turning to prevent lateral shifting of the goods due to centrifugal force.
Prohibit “forklift arm hitting the pallet”: If the forklift arm is not aligned correctly during picking up, manually adjust the pallet’s position rather than using the forklift arm to “push the pallet” (which can damage the pallet or shift the goods).
Pallet stacking: “Leave space + Height limit to prevent crushing and deformation.
If stacking multiple pallets (such as for temporary storage in a warehouse), ensure that the lower pallet can support the total weight of the upper pallets (e.g., if two pallets on the upper layer weigh a total of 1.5 tons, the lower pallet must be rated for 1.5 tons or more). When stacking, ensure that the edges are aligned (the upper and lower pallets should have a ≤5cm deviation) to avoid misalignment and excessive localized stress.
Stacking height should not exceed 3 layers (or as required by the airline), and a 5-10cm gap should be left between each layer (to facilitate ventilation and prevent the upper pallet from crushing the lower cargo packaging).
V. Advance Communication: Keep all parties synchronized to reduce accidents.
Cargo damage can sometimes stem from information asymmetry (e.g., unclear airline operating requirements and the freight forwarder’s failure to provide special precautions). Details must be confirmed in advance with the freight forwarder, airline, and warehouse:
Clarify “pallet cargo requirements” when booking.
Inquire in advance about the airline’s pallet restrictions: Maximum dimensions (length × width × Height), maximum load capacity, and whether wooden pallets are permitted (some airlines have additional inspection requirements for wooden pallets). If the cargo is “dangerous goods,” confirm the pallet’s “special reinforcement requirements” according to IATA regulations (e.g., dangerous goods require separate pallets, and the pallets must be leak-proof).
Inform the freight forwarder of “cargo vulnerability points”
If the cargo has “vulnerable areas” (e.g., glass on a certain side, or a component that is sensitive to pressure), inform the freight forwarder in writing in advance and mark the “vulnerable area” on the pallet (e.g., “Left side is fragile, please do not impact”) so that the freight forwarder can specifically remind the airline’s operators during handover.
Clarify storage requirements during temporary storage in the warehouse
If the cargo needs to be temporarily stored in the warehouse, inform the warehouse of “whether it can be stacked, whether it requires moisture protection, etc.” Protect goods from the sun (e.g., paper goods should be placed on wooden shelves to prevent moisture from the floor, and precision instruments should be kept out of direct sunlight) to prevent damage caused by improper storage (e.g., goods getting wet due to not covering them with tarpaulins on rainy days).
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