How to Load The Most Amount of Wooden Pallets on A Trailer Load

Maximize Trailer Space, Maintain Load Stability, and Avoid Costly Mistakes

Loading wooden pallets into a 53-foot dry van may seem straightforward, but the method you choose has major cost and efficiency implications. For standard 48x40 pallets, changing the orientation and stack pattern can be the difference between shipping 520 or 660 pallets per truckload.

This guide outlines the most effective loading strategies—primarily for standard 48x40 wooden pallets—and includes special considerations for odd-sized inventory.

Standard Pallet Load Configurations

Straight Loading

• Orientation: 48-inch side faces the trailer doors
• Typical configuration: 26 stacks × 20 pallets high
• Example: 26 × 20 = 520 pallets
• Range: 520 to 572 pallets (if stacked 22 high)

Straight loading is easy to execute and stable in transit. However, it leaves unused trailer width and wastes space.

Turned Loading

• Orientation: 40-inch side faces the trailer doors
• Typical configuration: 28 to 30 stacks × 20 to 22 pallets high
• Example: 28 × 22 = 616 pallets
• Range: 560 to 600+ pallets

Turning the pallets uses trailer width more efficiently than straight loading but may reduce stack stability slightly.

Pinwheeled Loading

• Orientation: Alternates between straight and turned rows
• Typical configuration: 30 to 33 stacks × 20 to 22 pallets high
• Example: 30 × 22 = 660 pallets
• Range: 600 to 660 pallets

Pinwheeling offers the highest capacity but requires careful planning and skilled forklift operation to prevent shifting.

Weight-Distribution Loading

• Orientation: Custom layout based on axle load limits
• Example: 24 stacks × 20 pallets = 480 pallets
• Range: Variable

This method prioritizes legal axle weight distribution over maximum count. It’s useful when you're close to a trailer’s 45,000 lb weight limit.

Why Many Warehouses Load Inefficiently

Most warehouses and vendors that are not dedicated pallet yards typically:

• Stack only 20 pallets high
• Use either straight or turned loading
• Load 22 to 26 stacks total
• Example: 24 stacks × 20 high = 480 pallets

That usually results in only 440 to 520 pallets per truck—well below the 660 that optimized layouts can achieve. The result is higher freight costs per pallet and wasted trailer capacity.

Recommendation for recyclers and buyers:
Encourage suppliers to switch to double pinwheeled loading. For example, 30 stacks × 22 pallets = 660 total pallets. Visual guides, floor tape, or even brief training can help improve compliance.

Odd-Sized Pallets

Although this guide is written primarily for 48x40 pallets, many facilities also handle odd-sized units or mixed loads.

Best Practices for Odd Sizes

• Keep each size grouped in its own load zone
• Don’t mix odd sizes with 48x40s in the same stack (your pallet recycler will love this)
• Measure and plan the floor layout before loading
• Expect lower capacity on non standard size loads

You’ll lose space compared to standard pallets, but dedicated layout planning can still prevent inefficiencies.

Loading Tips and Safety Considerations

Before You Load

• Inspect all pallets for broken boards or exposed nails
• Keep stack heights consistent within a load
• Strap or wrap uneven stacks for security
• Confirm weight if approaching trailer maximum capacity (usually ~45,000 lbs)

Forklift Technique

• Approach stacks squarely
• Level forks and fully insert into each stack
• Move slowly during tight placement, especially for pinwheeled loads

Recap: Pallet Loading Options

Straight Loading
26 stacks × 20 high = 520 pallets

Turned Loading
28 stacks × 22 high = 616 pallets

Pinwheeled Loading
30 stacks × 22 high = 660 pallets

Distribution Loading
24 stacks × 20 high = 480 pallets

Final Checklist Before Sealing the Trailer

• Are stacks uniform at 20 to 22 high?
• Is the loading orientation consistent (unless pinwheeled)?
• Are all stacks secure and damage-free?
• Are there no gaps between stacks that could allow shifting?
• Do trailer doors close smoothly without contact or pressure?

Conclusion: Every Load Counts

If you're coordinating pallet pickups or shipments, how you load matters more than most realize. Shifting from 520 to 660 pallets per truck can reduce freight cost per unit dramatically and increase recovery margins.

Whether you're moving broken pallets or high-grade cores, the right load method often pays for itself in one trip. Aim for pinwheeled or turned loads wherever possible, and standardize stack practices across all facilities.