Selecting the correct pallet dimensions might seem straightforward, but it is a decision that directly impacts freight costs, warehouse space utilisation, handling efficiency and product safety. The wrong size can lead to wasted truck capacity, incompatible racking systems and increased risk of product damage during transit. This guide walks you through the key factors to consider when choosing pallet dimensions for your business.
Understanding Standard Australian Pallet Sizes
In Australia, the most commonly used pallet size is the 1165 x 1165mm square pallet. This dimension has been the backbone of the domestic supply chain for decades and is designed to maximise the use of standard truck and container dimensions. Most Australian warehouses, distribution centres and retail operations are configured around this size, making it the default choice for businesses operating primarily within the domestic market.
However, if your goods move through international supply chains or you deal with European-origin products, you may also encounter the 1200 x 1000mm pallet — commonly referred to as the Euro pallet — and the 1200 x 800mm variant. These dimensions are standard across much of Europe and Asia and are optimised for different container and truck configurations.
Matching Pallet Size to Your Industry
Different industries have naturally gravitated towards specific pallet sizes based on the nature of their goods and their handling equipment:
- Retail and FMCG: The 1165 x 1165mm Australian standard is dominant. Supermarket distribution centres and retail chains have standardised on this size, and their racking and handling systems are designed accordingly.
- Chemical and pharmaceutical: The 1100 x 1100mm drum pallet is widely used because its dimensions align with the footprint of standard 200-litre drums arranged in a 2x2 configuration.
- Export and international trade: The 1200 x 1000mm pallet is often preferred for goods destined for international markets, as it optimises the floor space of 20-foot and 40-foot shipping containers.
- Airfreight: Lightweight pallets in non-standard sizes are common in airfreight, where dimensions are dictated by aircraft ULD (Unit Load Device) specifications and weight is a critical cost factor.
Key Factors to Consider
When deciding on a pallet size, several practical factors should guide your choice:
Transport method: Road freight within Australia is well-suited to the 1165mm standard. If your goods are going into shipping containers, measure the internal dimensions and calculate how many pallets will fit with minimal wasted floor space. A few centimetres of difference in pallet width can mean the difference between fitting two or three pallets across the container width.
Warehouse racking: Check the beam spacing and depth of your existing racking system. Your pallet must sit securely on the beams without excessive overhang or insufficient support. If you are setting up a new warehouse, it is worth selecting racking that matches the pallet size most commonly used in your industry.
Product dimensions: The pallet should be large enough to support your product footprint without significant overhang, which increases the risk of damage. Conversely, a pallet that is too large wastes space and adds unnecessary weight.
Load weight: Standard pallets are designed to support static loads of around 1,000 to 2,000 kilograms. If your goods are heavier, a reinforced or custom pallet may be needed regardless of the dimensions.
When to Consider Custom Sizes
If none of the standard sizes are a perfect fit for your application, custom-built pallets can offer significant efficiency gains. For example, a manufacturer shipping a specific product repeatedly may find that a purpose-designed pallet reduces packaging material, maximises container utilisation and speeds up the loading process. The upfront cost of custom pallets is often offset by ongoing freight savings and reduced product damage rates.
At Affordable Pallets, we manufacture both standard and bespoke pallets to suit any requirement. Our team can advise on the most efficient size for your specific application — get in touch or call (02) 9829 6899 for expert guidance.