Pallets for paper, corrugated and packaging products
Paper and packaging need flat, dry pallets with high deck coverage, because sheets and blanks take the shape of the deck and absorb moisture. Box and print plants often buy custom sizes per product. Rolls ship on end or in cradles for clamp trucks, and some light loads ship on slip sheets.
Paper and packaging products are some of the most demanding loads for a pallet's surface. A stack of printing paper or corrugated blanks takes on the shape of whatever it sits on: gaps between deckboards leave marks, cupped boards leave a bow, and damp wood leaves stains and curl. Strength matters too, since paper is dense, but flatness, coverage and moisture usually decide the design.
Which pallets does the paper and packaging industry use?
| Product | Typical base | Why |
|---|---|---|
| Ream cartons (copy and office paper) | 48 × 40 in stringer or block | Retail and office-supply DCs |
| Sheet paper for printing | Custom-size pallets with solid or near-solid top decks ("skids") | Sheets need full support; footprint matches sheet size |
| Corrugated boxes and blanks | Custom-size pallets, often 48 × 36 in or sized to the bundle | Orders vary in size; overhang crushes edges |
| Folding cartons | 48 × 40 in or custom | Customer requirements |
| Tissue and towel | 48 × 40 in pallets, or slip sheets with push-pull or clamp handling | Light, bulky loads; cube matters more than weight |
| Paper rolls | On end, or on cradles or skids; clamp trucks | Roll geometry |
| Export shipments | ISPM 15 HT wood, or paper pallets | Phytosanitary rules; paper is exempt |
Common requirements
- Deck coverage. Higher top-deck coverage (narrower gaps, wider boards, or a solid deck) prevents board marks on sheets and blanks. A tier sheet of fiberboard or chipboard on the deck is a common alternative.
- Flatness. Deckboards must be flat and level; warped boards cause bowed stacks and feeding problems in printing presses and box plants.
- Dry lumber. Wet or green wood transfers moisture to paper, causing curl, staining and mold. Specify kiln-dried or low-moisture lumber. See pallet lumber moisture.
- No protruding fasteners or splinters. They damage the bottom sheets.
- Custom sizes. A pallet matched to the load avoids overhang (crushed edges) and large underhang (wasted space). Box plants often buy several sizes in small quantities.
- Clamp and push-pull handling. Many paper and tissue warehouses use clamp trucks or push-pull attachments; loads on slip sheets must be designed for them. See pallet vs slip sheet.
Typical loads and weights
Paper is dense. Typical gross weights (estimates):
| Load | Typical weight |
|---|---|
| Copy paper, 40 cartons of 10 reams | About 2,000 lb plus pallet |
| Sheet paper stacks for printing | 2,000 to 3,500 lb, depending on sheet size and height |
| Corrugated boxes (flat, bundled) | 500 to 1,500 lb |
| Tissue and towel | Often under 1,000 lb; cube-limited |
Heavy sheet stacks put a near-uniform load on the whole deck, which is kind to the pallet. If they are double-stacked, the bottom pallet must carry both.
Pallets inside paper and box plants
Mills and converting plants also run in-house pallets between machines: roll handling, sheeting, die-cutting and finishing. These pallets often need tight dimensional tolerances for conveyors and automated storage, and closed loops make plastic or heavy reusable wood worth considering. Keep in-plant pallets separate from one-way shipping pallets so worn units do not leave with customer orders.
Common pitfalls
- Standard pallets with wide gaps under sheets. Board marks, sheet damage and wasted product.
- Green lumber. Curl and mold on the bottom of the stack, especially in containers.
- Overhang of corrugated bundles. Edges crush and boxes fail compression tests.
- One size for all orders. Leads to overhang or unstable underhang; a small set of custom sizes usually pays back.
- Ignoring clamp handling. Pallet loads that clamp trucks cannot grip without damage.
Spec checklist for a quote
- Footprint matched to the product (list all sizes needed) and overall height
- Top deck: coverage or maximum gap, board width, solid deck or tier sheet
- Flatness requirement
- Lumber: species group, kiln dried, maximum moisture content
- Fasteners: countersunk or flush, no protrusions
- Load: product type, stack height, gross weight, double-stacking
- Handling: forklift, pallet jack, clamp truck, push-pull
- ISPM 15 HT or exempt material for export
- Quantities per size and delivery cadence
To request a custom size, start from any stringer template and set the footprint and deck spacing in the designer, or see the paper pallet template and slip sheet template for alternatives.
Frequently asked questions
Why do paper and corrugated products need special pallets?
Sheets and flat blanks take the imprint of gaps between deckboards and can bow over them. Paper also absorbs moisture from wet wood. Pallets with high deck coverage, flat surfaces and dry lumber prevent both.
What size pallet is used for corrugated boxes?
Often a custom size matched to the bundle footprint, because corrugated orders vary. Standard 48 × 40 in pallets are used when the customer's warehouse requires them, with the load sized to avoid overhang.
How much does a pallet of copy paper weigh?
A common pallet is 40 cartons of 10 reams of letter paper, about 50 lb per carton, so roughly 2,000 lb plus the pallet. Counts vary by paper weight and supplier.
Are paper rolls shipped on pallets?
Usually not. Large rolls ship on end and are handled with clamp trucks, or on their side in cradles or on skids. Small rolls and cores can be palletized.
Sources and references
- Uniform Standard for Wood Pallets (Woodpack Global, formerly NWPCA)
- ANSI MH1-2021, Pallets, Slip Sheets, and Other Bases for Unit Loads (MHI)
Related
- TypesSlip sheet: the thin pallet alternative, sizes, tabs and materialsA slip sheet is a thin sheet of solid fiberboard, corrugated board or plastic used under a unit load instead of a pallet. A push-pull lift truck attachment grips its tab and pulls the load onto its platens. Sheets for a 40 × 48 in load are commonly 43 × 51 or 44 × 52 in with 3–4 in tabs.
- TypesPaper pallet: corrugated and honeycomb pallets explainedA paper pallet is made entirely from paper products: a corrugated or honeycomb paperboard deck on feet of paper tubes, honeycomb blocks or folded board. It is very light (from about 4 kg, 9 lb), recyclable and ISPM 15 exempt. Ratings reach about 750–1,000 kg, and humidity reduces strength.
- GlossaryDeck coverage (pallet)Deck coverage is the percentage of a pallet deck's area that is covered by deckboards. A GMA-style 48 × 40 top deck covers about 59%; a solid deck covers 100%.
- GlossaryCorrugated fiberboard (pallets and slip sheets)Corrugated fiberboard is a board made of a fluted paper medium glued between flat paper liners. It is used for boxes, and in pallet work for corrugated paper pallets, slip sheets, tier sheets and pallet runners.
- Sizes48 × 36 pallet: dimensions, weight and specsA 48 × 36 in pallet (1219 × 914 mm) is a North American size used for beverages, roofing shingles and packaged paper. It is usually a 3-stringer wood pallet with 36 in deckboards, about 4.75 in tall and roughly 27 to 56 lb.
- GuidesPallet lumber moisture: green vs kiln-dried, shrinkage, weight and moldGreen pallet lumber can hold 50–80% moisture; kiln-dried (KD) lumber is dried to about 19% or less. Drier wood is lighter, stiffer and far less prone to mold, but green wood nails more easily and costs less. Heat treatment (HT) for ISPM 15 kills pests; it does not dry the pallet. Specify moisture separately.
- GlossaryTier sheetA tier sheet (layer pad) is a flat sheet of corrugated board, solid fiber or plastic placed between layers of a unit load, or on the pallet deck, to spread weight, bridge deck gaps and stabilize the layers. It is not lifted by equipment.
- ComparisonsPallet vs slip sheet: cost, cube and handling comparedChoose a slip sheet when you ship high volumes in containers or trucks, both ends have push-pull forklift attachments, and saving weight, cube and pallet cost matters. Choose a pallet when the receiver handles with standard forks or pallet jacks, loads are racked, or handling equipment is unknown.
More in Industries
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Last reviewed 2026-09-24. 747 words.