In domestic freight, small layout decisions can change cost per shipment. Better pallet configuration means fewer partially empty trailers and fewer total trips.
Start With Standard 48x40
For most dry van loads, 48x40 pallets are still the most efficient standard. They align with common warehouse workflows and maximize compatibility.
Pinwheel vs Straight Load
Pinwheel patterns often improve stability and reduce voids for mixed-case loads. Straight loads may be faster for uniform SKUs and automated handling.
Account for Product Overhang
A layout that looks efficient on paper may fail if cartons overhang deck edges. Model real product dimensions, not just pallet footprints.
Standardize by Lane
If the same customers receive the same SKU mix weekly, predefine loading templates. Teams load faster and damage rates drop.
Even a 3 to 5% improvement in cube utilization can produce meaningful annual freight savings.