Loading products onto a pallet is only half the battle. If the load isn't properly secured, it can shift during transit, causing product damage, truck driver injuries, and rejected shipments. Here are the essential techniques for securing pallet loads.
Stretch Wrapping
Stretch wrap (stretch film) is the most common load securing method. This thin, elastic plastic film is wrapped around the load and pallet, creating a tight, unitized package. For best results, always anchor the wrap to the pallet base before wrapping the load — this prevents the load from sliding off the pallet. Use at least 3-5 layers at the base, 2-3 layers around the body, and extra layers at the top.
Machine wrapping (using a stretch wrapper) produces more consistent results than hand wrapping and uses less film per load. If you wrap more than 15-20 loads per day, a semi-automatic stretch wrapper pays for itself quickly.
Strapping
Steel or polyester strapping provides additional security for heavy or irregularly shaped loads. Straps are tensioned around the load using manual or pneumatic tools and secured with seals or heat welding. Strapping is especially important for loads that can't be effectively stretch-wrapped, such as lumber, pipe, or irregular shapes.
Corner Boards
Cardboard or plastic corner protectors (edge boards) serve two purposes: they protect the product from strap damage, and they distribute strapping or wrapping force over a larger area, preventing crushing. Always use corner boards when strapping — the cost is minimal and they significantly reduce product damage.
Stacking Patterns
How you stack boxes on a pallet matters. Interlocking patterns (where each layer rotates 90 degrees from the previous one) create a more stable unit load than column stacking (where each layer is identical). Interlocking does slightly reduce the number of cases per pallet, but the improvement in load stability is well worth it.
Anti-Slip Sheets
For smooth-surfaced products (shrink-wrapped cases, plastic totes), place anti-slip sheets between layers. These rubberized or textured sheets dramatically increase friction between layers, preventing sliding without additional strapping or wrapping.
Common Mistakes to Avoid
Wrapping only the load without anchoring to the pallet, using too little stretch wrap (false economy), overhanging product beyond the pallet edge (causes fork damage and instability), not using corner boards with strapping, and pyramiding loads without proper containment.