Pallet Prep Done Properly: How to Avoid Collection Problems

Booking a pallet delivery should be simple. Measure your goods, book the service, get everything collected and wait for it to arrive. Lovely stuff.

Except, sometimes, the smallest details cause the biggest headaches.

A pallet that overhangs by a few centimetres. A second-hand pallet that has seen better days. A fragile item wrapped in shrink wrap but not actually protected. You get the idea.

Most pallet collection problems happen because pallet freight has a few important rules that are easy to miss, especially if you do not send pallets every week.

So, before the driver arrives, here is what to check to help avoid refused collections, delays, unexpected charges and damage in transit.

1. Choose the right pallet size

Before anything goes anywhere, you need to know what size pallet you are sending.

At PalletOnline, you can book different pallet sizes depending on the height, weight and footprint of your goods, including micro, quarter, half, full and oversized pallets. The important bit is measuring everything once it is fully packed and ready to travel.

That means including the pallet base, packaging, wrapping, strapping, full height from the ground up and the total weight of the goods and pallet together.

Not just the item. Not just the box. Not just a hopeful estimate from across the garage.

If your pallet sits between two sizes, book the bigger option. Booking too small can lead to your pallet being upgraded and an additional charge being applied. Booking too big will still get your pallet delivered, but you will not be refunded for unused space.

2. Check for overhang and oversized freight

One of the most common pallet delivery problems is overhang.

Your goods should fit within the pallet edges. If they stick out beyond the pallet base, they can take up extra vehicle space, become harder to handle, or risk damaging other freight. In many cases, this means your shipment needs to be booked as an oversized pallet.

Oversized pallets are useful for bulky, awkward or larger freight, but they come with extra requirements. For example, oversized pallet deliveries require a forklift or similar loading equipment at both collection and delivery points.

If you are unsure whether your pallet counts as oversized, check before booking. It is easier to choose the right option upfront than to deal with delays or extra charges later.

3. Use a pallet base that can handle the job

The pallet itself matters just as much as the goods on top of it.

Your goods must be placed on a strong, undamaged pallet base that can safely carry the weight during handling and transport. A pallet may look fine at first glance, but if it has broken boards, missing blocks, exposed nails or signs of weakness, it may not be suitable.

A good pallet base should be strong enough for the load, complete, flat, free from visible damage and suitable for forklifts and pallet trucks. It should also be accessible from at least two sides.

If you are using a second-hand pallet, give it a proper check before loading your goods. Has it been stored outside? Is it warped? Are any boards loose?

If the pallet base looks questionable, replace it before collection.

4. Pack your pallet so it can actually travel

Pallets do not travel in a completely still, untouched bubble. They are loaded, unloaded, moved through depots, handled by pallet trucks or forklifts and transported alongside other freight.

That means your pallet needs to be packed securely enough to handle the journey.

Stack goods evenly, keeping boxes flat, level and tight. Heavy items should go at the bottom, lighter items on top, and the overall load should feel stable before it is wrapped.

If your goods are not boxed, they still need to sit flat on the pallet and be secured properly. Non-boxed items can be more awkward to move, so do not rely on shrink wrap alone if the item could shift, tip or roll.

Loose items will not be collected unless you have booked a Pallet & Wrap service. If you have not booked this, your goods must be palletised and fully secured before the driver arrives.

Pallet trucks cannot be used safely on gravel, grass or uneven ground, so your pallet needs to be on a flat, solid surface where the driver can access it.

5. Wrap, secure and protect your goods

Shrink wrap is useful. It helps secure goods, reduces movement and protects against scuffs during handling.

What it does not do is make your pallet invincible.

When wrapping your pallet, start at the base and work upwards. The wrap should go around both the goods and the pallet base, so the load is held together as one secure unit.

If your goods need extra support, use securing methods such as ratchet straps, plastic or metal banding, edge protectors, cardboard guards, netting or sheeting.

Shrink wrap also does not make your goods waterproof. If your goods cannot get wet, they need proper weather-resistant packaging.

If your goods can move, shift, roll or fall, they need more securing.

6. Label anything fragile, heavy or non-stackable

If your pallet needs special handling, make that clear.

Fragile, heavy, liquid or non-stackable goods should be labelled properly so they can be handled as safely as possible. If your pallet must not be stacked, use visible “Do Not Stack” labels, tape or a pallet cone.

Labels should be clear, easy to read, visible from all sides and not hidden under layers of shrink wrap. Use “Fragile”, “Handle with Care” and orientation labels where needed.

The pallet network does not guarantee your pallet will not be stacked unless this is clearly marked. So, if stacking could damage your goods, do not leave it to chance.

7. Check whether your goods need special preparation

Some goods need more than standard wrapping and strapping. Bagged goods, glass, barrels, kegs, sharp goods, batteries and hazardous goods all have more specific requirements.

For example, glass needs strong outer protection, barrels and kegs must be strapped, sharp goods must be fully contained, and hazardous goods can only travel through the pallet network if they meet Limited Quantity requirements.

Engines and gearboxes also need specific preparation before they can travel through the pallet network. They must be securely supported, fully drained of fluids and packed in line with the latest network requirements, so it is important to check our dedicated engine and gearbox help page before booking. 

This is where it is worth checking the relevant help page before booking. A standard pallet guide can point you in the right direction, but some goods need more specific instructions to travel safely and compliantly.

8. Understand what Pallet & Wrap does and does not include

Pallet & Wrap can be helpful if your goods are loose and need to be placed on a pallet before delivery.

With this service, the pallet and shrink wrap are supplied, and the driver will assist with loading and wrapping at collection. However, the key word here is assist.

Your items still need to be ready to load. The driver is not there to completely pack, prepare and secure everything from scratch while everyone stands around pretending this was always the plan.

Straps are not included, so if your goods need extra securing, such as ratchet straps, you must provide these yourself. Pallet & Wrap also does not make your goods weatherproof.

9. Do one final check before collection

Before the driver arrives, take five minutes to check your pallet properly.

Ask yourself:

• Have I measured the pallet after packing?
• Have I booked the correct pallet size?
• Does anything overhang the pallet edges?
• Is the pallet base strong and undamaged?
• Are the goods stacked evenly and securely?
• Have I wrapped the pallet from base to top?
• Are warning labels visible on all sides?
• Are the goods protected from the weather?
• Is the pallet on flat, solid ground?
• Are my PalletOnline labels printed and attached?
• Have I checked the rules for any special goods?

If the answer to any of these is “not sure”, it is worth sorting before collection.

Because the best time to fix a pallet problem is before the driver arrives. The second-best time is definitely not when the driver is standing there, the pallet is leaning and everyone is quietly hoping shrink wrap can perform miracles.

Need help before you book?

If you are unsure which pallet size to choose, whether your goods count as oversized, or how your freight should be prepared, our team can help before you book.

Check the relevant help articles or speak to us on Live Chat.

A few extra checks now can save a lot of hassle later and make your pallet collection much smoother from the start.