How to minimise the risk of pallet rejections

No shipper wants to go through the process of preparing a pallet for shipment, only for their freight to be rejected when it’s time for pickup. And yet, it’s an all too common scenario. At the end of 2024, pallet rejection rates stood at 8%. That means almost one in 10 shipments were turned away.

It’s not that freight providers want a pallet rejected. After all, businesses like Amazon Freight depend on accepting pallets from shippers. However, at the same time, freight providers must adhere to strict compliance standards. These are in place to ensure the safety, efficiency, and accuracy of all freight transportation.

In this article, we’ll explain the most common reasons behind pallet rejections, and give you detailed advice on how to ensure your loads are always compliant and accepted.

Rejected pallets are, undoubtedly, a costly inconvenience for shippers. Just one load refusal can trigger a ripple effect across the supply chain, causing operational delays, a loss of customer trust, and erode the bottom line.

The good news is that these rejections are entirely avoidable. By adhering closely to freight provider requirements, shippers can ensure their pallets are accepted each and every time.

Pallet rejections can happen for several reasons—each of which links back to your freight provider’s internal compliance policies.

Here’s an overview of the factors that typically trigger a rejection:

Freight providers typically use standardised pallet dimensions to ensure seamless, efficient handling. Incorrectly sized pallets (or pallets made of non-compliant materials) are likely to be rejected.

Poorly stacked loads present the risk of shifting or collapsing during transit. If your freight provider deems a palette unstable, they may turn it away.

Products that extend beyond the pallet’s edge are more likely to be damaged in transit. Freight carriers are likely to decline palettes with overhanging goods.

Correct labelling is crucial to ensure your palette gets to its destination. If labels are missing, unclear, or placed incorrectly, your palette may be refused.

Cracked or broken bases are a huge safety risk, so are always rejected from a compliance perspective.

Overweight pallets can exceed handling thresholds or vehicle limits, triggering surcharges or rejection due to safety concerns.

All of the factors that can trigger a freight rejection have their routes in safety and efficiency. For shippers and freight providers, pallet compliance isn’t just a tick-box—it’s paramount to maintaining an optimum supply chain.

Here are the best practices to follow to prepare a pallet compliantly.

While there is no single global standard for pallet size, you can look to UK and EU requirements for guidance. For UK-based shippers, the recommended pallet size is 1.0m x 1.2m. The EU typically uses 1.2m x 0.8m pallets. If you ship pallets with Amazon Freight, we recommend adhering to the UK standard to ensure compatibility with our fulfilment systems.

All pallets must be structurally sound and capable of supporting the full weight of the load throughout handling and transit. We recommend using wooden pallets with four-way entry—allowing access from all sides by forklifts.

As well as this, your pallet materials must be free from damage. Cracked boards, loose nails, or signs of warping can compromise cargo integrity. Materials should be rigid and maintain their form under load. If needed, you can use reinforced solutions like triple-ply cardboard for heavier shipments.

How you stack your pallets is just as important as the quality of the pallets themselves. Here are some best practices to keep in mind:

• Weight distribution: The heaviest items should be placed at the base of the pallet, with lighter and more fragile items above
• Stacking: Boxes should be stacked in vertical, interlocking columns—similar to a brick-laying pattern—to maximise structural stability/
• No overhang: Items must not extend more than 1 inch beyond the pallet’s edge
  Fragile goods: Position these near the centre of the pallet for added protection.
  Sharp or irregular items: Wrap with appropriate padding to prevent damage to other packages
• Load height: Ensure the final load height does not exceed 90 cm (for stacked pallets) or 1.8 m (72 inches) for non-stacked configurations

Once you’ve stacked your pallet, you’ll need to securely wrap it to minimise movement during transit. Stretch wrapping is the industry standard. Depending on the contents of your load, you may need to use additional measures like bracing lumber, edge boards, load protectors, strapping, or foam inserts.

Last, but certainly not least, it’s crucial to label your pallet accurately. This is the final hurdle that catches some shippers. Improper or missing labels can cause even a perfectly wrapped pallet to be turned away.

Here’s what to keep in mind:

• Label each pallet on all four sides: All pallets must be clearly labelled on all four sides (note, this is for Less Than Truckload (LTL) shipments only)
• Visibility is crucial: Affix each label at a consistent height on each side of the pallet, ensuring each one is clearly visible
• Use smudge-resistant labels: Use durable, smudge-resistant labels that can withstand handling, moisture, and temperature fluctuations during transit

Now, you’re ready to declare your load and ship your palletised freight. During the declaration process, you’ll need to share your pallet dimensions, along with the pallet weight. Accuracy is critical during this step. If your measurements aren’t right, your pallet may be rejected—or you could incur additional surcharges.

Here’s what to do:

Pallet dimensions must include the full footprint of the pallet, including both the base and the goods loaded on top. You should measure the longest side of the pallet base, the shorter side, and the height (the floor to the highest point of the load), and input these details.

The declared weight should reflect the total weight of the pallet. That means the weight of both the goods and the pallet itself. Use calibrated scales to determine this figure.

Amazon Freight simplifies and streamlines the process of shipping palletised freight, giving you convenience and confidence for every shipment.

Our intuitive web portal gives you complete control of the booking process, with fully-transparent spot and contract rates. Whether you need a single pallet collected, a full truckload (FTL), or several pallets going to multiple destinations, we can collect your pallets in a single pickup. All the labels you need are taken care of by us—printable within our easy-to-use online system.

Avoiding pallet rejections is simple once you standardise how you approach preparing pallets for shipping. Keep this handy checklist in mind for each and every shipment:

• Use the correct pallet size: 1.0m x 1.2m for shipments with Amazon Freight
• Pack securely and stack stably: Stack in interlocking columns, avoid overhang, place heavy items at the bottom, and keep the load within the height and weight limits
• Label clearly and correctly: Affix labels on all four sides (LTL only), ensure labels are visible and smudge-resistant, and remove any old or conflicting labels
• Measure and declare dimensions accurately: Include the full pallet footprint and height. Weigh the entire pallet (including the base) using calibrated scales
• Inspect pallet condition: Only use rigid, high-quality pallets with four-way entry. Avoid cracked boards, warping or loose nails

Amazon Freight is your trusted partner for secure, efficient, and flexible pallet shipping. Join thousands of shippers using our extensive logistics network, GPS enabled trailers, and simple booking system to optimise their freight shipments.

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