Two-way vs four-way pallets: entry types explained

"Way" means how many sides of the pallet accept forks. It is set by the pallet's base: continuous stringers block entry from the sides, notches open a path for forklift tines, and blocks leave openings on every side. See fork entry.

#Side-by-side comparison

#Two-way pallets

A two-way pallet has continuous stringers with no notches, so forks enter only at the ends. The full stringer depth gives the most bending strength for the lumber used, which makes two-way designs common for heavy loads, machinery and custom pallets moved in one direction. The downside is flexibility: the pallet has to be presented to the forklift end-on, which costs time in trailer loading and tight aisles.

#Partial four-way pallets

Cutting two notches in the bottom of each stringer lets forklift tines enter from the sides. That is the standard GMA-style stringer pallet. The Uniform Standard for Wood Pallets gives recommended notch dimensions (about 9 in long, with a minimum flat top and rounded corners) so the notch does not weaken the stringer too much. Pallet jacks still enter only from the ends, because their wheels need to reach the floor through the bottom deck. See partial four-way.

Notching removes wood where bending stress is highest, so notched stringers carry less than solid ones of the same size. Designers compensate with deeper or stronger stringers when the load needs it.

#Full four-way pallets

A four-way pallet has full-height openings on all four sides. In wood this means a block pallet. Whether a pallet jack can enter all four sides depends on the bottom deck: a perimeter or cruciform bottom with wheel openings allows it, a unidirectional bottom allows jack entry from two sides. Most molded plastic pallets are four-way.

Four-way entry speeds up cross-docking, side-loading trailers and working in narrow aisles, and it lets automated systems handle a pallet regardless of orientation.

#Cost

Entry type is a small cost driver on stringer pallets and a large one between classes. Notching adds a machining step to each stringer, typically a small addition to the price of a stringer pallet, and may call for a deeper stringer to keep the same capacity. Moving to full 4-way usually means a block pallet, with more components and more labor per pallet. For the price range of a standard 48 × 40 in pallet and what moves it, see pallet cost. Pooled 4-way block pallets are rented rather than bought; see pooled vs white wood.

#How entry affects racking and trailers

Entry and racking interact. A stringer pallet is strongest when its stringers span the rack beams, so it is usually loaded into selective racking from the end, with forks between the stringers. With partial 4-way pallets, forklift drivers sometimes enter from the side and set the pallet with stringers parallel to the beams, where deckboards alone carry the span. That orientation can overload deckboards; see racked across length and racked across width.

In trailers, 48 × 40 in pallets can go straight (26 in a 53 ft trailer) or turned (30). Turning requires entering from the side, so 4-way entry directly affects trailer utilization. See pallets per truckload.

#When to choose each

Choose two-way when: loads are heavy and handled in one direction; you want maximum stringer strength per dollar; the pallet is custom and runs in a fixed process.

Choose partial four-way when: you want the standard low-cost 48 × 40 in stringer pallet and forklift access from all sides is enough.

Choose full four-way when: pallet jacks must enter from the sides; pallets are turned often or loaded sideways into trailers; you use automation, pooling or export block pallets.

For the construction trade-offs behind this, see block vs stringer pallets. You can open the GMA template in the designer and change the notches, or start from a block pallet.