Pallet shipping lets your business move heavy or multi-box consignments as one unit so your goods are handled less and arrive together. Whether you're sending palletised stock from Ireland to the European Union (EU), Great Britain, or further overseas, a well-prepared pallet keeps delivery smooth and costs predictable. This guide walks you through choosing a pallet, packing, wrapping, measuring, labelling, paperwork, and shipping with DHL Express.

What is pallet shipping and when should you use it?

A pallet is a flat, sturdy base that allows goods to be stacked so that it can be handled by forklifts and moved as a single unit. 

There are many clear advantages to palletising your shipment:

• Fewer handling touchpoints: Handlers move one unit rather than dozens of individual boxes.

• Ship multiple items together: If you are shipping multiple items with varying weights or dimensions, pallestising allows you to ship them together for the entire journey.

• Faster loading: Pallets make loading and unloading easier and quicker.

• Better protection: Goods are stacked and stabilised as one unit, which helps prevent damage from shifting or pressure.

   

It's usually time to palletise when you're shipping:

• Multiple boxes to the same destination

• Heavy or awkwardly shaped items

• Fragile or high-value goods that need a stable base

• Loads too heavy to lift safely by hand

   

The weight of your shipment matters too. DHL Express requires items over 70 kg to be loaded onto a pallet.

If you're sending a large item you won't be palletising, explore this DHL Express guide on how to pack large and heavy shipments.

How to choose the right pallet for shipping

The right pallet keeps your load stable, easy to handle, and ready for export. Here's what to consider before you start loading.

 

Pallet materials

Pallets can be made out of different materials, which affects its physical characteristics and its recommended load.

Material	Strength	Weight	Reusable	Suitable for export
Wood	Strong; suits most shipments, including heavy loads	Heavier	Yes	Yes, if ISPM-15 marked
Plastic	Durable	Varies by design	Yes, and easy to clean	Yes
Presswood (composite) or cardboard	Generally lower load capacity	Lightweight	Usually used for one-way exports	Yes

Wood is the most common choice, while plastic's water resistance makes it popular in industries such as food and healthcare.

 

Pallet sizes

The most common pallet sizes on shipping routes from Ireland are:

• EUR pallet (Euro pallet): 1,200 × 800 mm

• United Kingdom (UK) standard pallet: 1,200 × 1,000 mm

• North American pallet: 48 × 40 inches

As a rule of thumb, match your pallet size to the destination. Using the local standard ensures your pallet fits the receiver's racking and handling equipment.

 

Two-way vs four-way entry

A pallet’s entry describes how a forklift or pallet truck can pick up your pallet:

• Two-way entry: Forks can only enter from two opposite sides.

• Four-way entry: Forks can enter from all four sides.

Generally, most places will prefer four-way entry pallets because they're easier to handle with a forklift, whichever way the pallet is facing.

 

Pallet condition

Check your pallet carefully before you load it. Look for:

• Cracked or missing boards

• Protruding nails

• Damp or waterlogged wood, which can warp under load

• Any other signs of damage that could weaken the base

If your pallet is wooden and heading outside the EU, you will also need to check if it has the ISPM-15 mark.
 

ISPM-15 rules for shipping wooden pallets overseas

If your goods leave the EU on a wooden pallet, the pallet has to meet ISPM-15 (International Standard for Phytosanitary Measures No. 15) standards. Developed by the International Plant Protection Convention (IPPC), the ISPM-15 is designed to reduce the risk of wooden packaging carrying pests across borders.

 

What the rules require

ISPM-15 covers wood packaging material such as pallets, crates, dunnage, and pallet collars.3 The wood must be debarked, then treated and officially marked.

In Ireland, the National Standards Authority of Ireland (NSAI) runs the ISPM-15 certification programme on behalf of the Department of Agriculture, Food and the Marine.

 

How to recognise a compliant pallet

A compliant pallet carries an official stamp on the wood. Look for:

• The IPPC symbol

• A two-letter country code, such as 'IE' for Ireland

• A producer code identifying who made or treated the pallet

• A treatment code showing how the wood was treated

'HT', for example, stands for heat treatment. This means the wood has been heated to 56°C for at least 30 continuous minutes right through to its core.

 

Which pallets are exempt

You don't need an ISPM-15 mark on:

• Plastic pallets

• Presswood pallets and other processed wood made with glue, heat, and pressure, such as plywood

• Cardboard pallets

• Wood that's 6 mm thick or less

   

What happens if a pallet isn't compliant

At the destination, a pallet without the right mark can be held while authorities decide what to do. Your goods may need re-palletising, and the non-compliant wood may be treated or destroyed, or the shipment sent back.4 Any of these can add delays and costs, so using a marked pallet from the start is the simplest way to prevent shipping issues. 

 

Where the rules apply

When shipping pallets overseas, you must comply with the destination country’s rules. Most countries outside the EU have adopted ISPM-15, but it doesn't generally apply to trade between EU countries.

 How to pack a pallet for shipping, step by step

When packaging is done right, a pallet load is well-balanced, stable and its edges are protected from impacts. 

 

Step 1: Box your goods first

Start with strong boxes. Use double-walled or triple-walled corrugated boxes for heavy or fragile items, and cushion the contents with foam inserts, bubble wrap, or air pillows so nothing moves inside.

Seal every seam using the H-taping method. For a step-by-step guide, read how to prepare your package for international shipping.

 

Step 2: Plan your weight distribution

A balanced load is a stable load. Follow these guidelines to ensure your load is evenly distributed:

• Place the heaviest boxes at the bottom and towards the centre.

• Put lighter boxes on top.

• Surround fragile items with sturdier goods in the middle layers.

• Keep the centre of gravity low to reduce the risk of tipping.

 

Step 3: Choose a stacking pattern

There are two main ways to stack your boxes:

• Column stacking: Boxes sit directly on top of each other, corner to corner. This works best when all your boxes are the same size, as the corners carry the weight.

• Interlocking (brick) stacking: Each layer is rotated or offset, like bricks in a wall. This adds stability to mixed loads.

Avoid pyramid stacking. It reduces load strength and can make your pallet non-stackable.

 

Step 4: Keep within the pallet footprint

Your goods should never extend beyond the pallet's edges. Overhang leaves boxes exposed to forklifts, racking, and other freight. Underhang, where the load stops well short of the edges, wastes space and gives boxes room to shift.

 

Step 5: Add edge and layer protection

 

A few extra materials along the edge of the pallet’s load and between in its layers can go a long way to protect the items you’re shipping:

• Corner boards: These protect the vertical edges of your load.

• Tier sheets or slip sheets: Placed between layers, these spread the weight and add stability.

• Pallet collars: Useful for loose or irregular goods. If they're wooden, they need an ISPM-15 mark too.

How to wrap and strap a pallet securely

Stretch wrap and straps turn a stack of boxes into a single, secure unit. Even a perfectly stacked pallet can shift if it isn't secured properly.

 

Strapping

Straps add extra security for heavy or tall loads, or goods likely to shift. You can choose from:

• Heavy-duty plastic straps: Strong and practical for most palletised loads

• Steel straps: Best for very heavy or dense loads

• Ratchet straps: Adjustable and reusable

Use at least two straps running perpendicular to the pallet base, threaded through the pallet so the load is tied to it. For taller loads, add cross-strapping.

 

Stretch wrapping

Follow these steps for a tight, secure wrap:

1. Anchor the end of the film to a corner of the pallet base.

2. Wrap the base at least three times, making sure the film covers the pallet itself so the load is anchored to it.

3. Work upwards, overlapping each layer and keeping the film under tension.

4. Wrap the top at least three times, then cap the top of the load.

Try a simple tightness check. If you can slide your hand between the film and the boxes, the wrap is too loose.

 

Order of work

Secure your pallet in three stages: corner boards, then straps, then stretch wrap. 

Fit the corner boards first, so the straps press against the boards rather than cutting into the edges of your boxes. 

Next, strap the load firmly to the pallet. 

Finish with stretch wrap, which holds everything in place, straps included, and stops the load from shifting during handling. 

Once you're done, check that your barcodes and labels are still clearly visible.

 

Stackable vs non-stackable pallets

Whether your pallet can bear weight on top affects both cost and handling. It's worth knowing which category your shipment falls into before you book.

• Stackable pallet: Has a flat, level, strong top that can safely support another pallet.

• Non-stackable pallet: Has a fragile, irregular, or pointed top, or contains goods that can't bear weight.

Non-stackable pallets take up space that other freight can't use, so a logistics provider may apply a surcharge for odd-shaped or non-stackable items.

 

To make your pallet stackable where possible:

• Level the top layer so it sits flat.

• Add a top board or cap to spread the weight.

• Avoid pyramid stacking.

• Keep everything within the pallet footprint.

 

Always declare stackability accurately. A pallet declared as stackable that can't take weight could end up damaged, and it may still incur a non-stackable surcharge. If your pallet can't be stacked, add a 'DO NOT STACK' label (see the labelling section).

 

How to measure and weigh a pallet for shipping

Accurate measurements help you get the right quote and avoid adjustments later. Measure and weigh the pallet once it's fully loaded and wrapped.

Use a reliable tape measure and scale, and measure:

• Length, width, and height at the longest, widest, and tallest points

• The pallet base as part of the height, and any overhang as part of the length and width

Then weigh everything together: pallet, goods, and packaging.

 

Understanding volumetric weight

Carriers look at space as well as weight. DHL Express charges on the greater of a shipment's actual weight or volumetric weight.

To calculate volumetric weight, multiply length × width × height in centimetres, then divide by the carrier's volumetric divisor. DHL Express uses a divisor of 5,000 for centimetres and kilograms.

For example, a loaded EUR pallet measuring 120 × 80 × 150 cm has a volumetric weight of 288 kg. If the actual weight is 200 kg, you'll be charged 288 kg. Keeping your load compact helps keep costs down.

You can check rates and volumetric weight when you get a rate quote.

 

Why accuracy matters

DHL Express may verify the declared weight and dimensions of your shipment, and additional charges may apply if there are discrepancies. Measuring carefully before you book helps you avoid re-weighing, re-rating, and unexpected fees.

 

Labelling a pallet and preparing shipping documents

Clear labels and complete paperwork help your pallet move through the network and customs without delay. Here's how to get both right.

 

Labels

DHL Express recommends attaching shipping labels and handling markings to all sides and the top of the pallet. Also make sure to:

• Keep barcodes flat, visible, and clear of stretch wrap.

• Use handling labels such as 'FRAGILE', 'THIS WAY UP', and 'DO NOT STACK' where they apply.

• Add heavy-package labels showing the weight, so handlers know what they're lifting.

• Number each pallet in a multi-pallet shipment, for example '1 of 3', '2 of 3', and '3 of 3'.

Attach a clear, self-adhesive document pouch to the outside of the pallet to hold any paperwork that needs to travel with it.

 

Documents

International pallets usually need:

• A waybill

• A commercial invoice

• A packing list

• Any licences or certificates your goods require, such as a certificate of origin

For a full explanation of each document, read what documents you need for international shipping.

Make sure your packing list matches exactly what's on each pallet. Your invoice should also match the contents of your shipment and the details on the waybill.

 

Shipping pallets overseas from Ireland

The processes associated with international pallet shipping from Ireland changes depending on whether your pallet stays within the EU or leaves it. Knowing which rules apply helps you plan the right paperwork from the start.

Within the EU, most goods can move freely between EU countries without customs declarations, thanks to the EU Single Market.5 Goods in free circulation aren't subject to customs supervision, although VAT (value-added tax) obligations still vary depending on what you're selling and to whom. ISPM-15 doesn't generally apply either.

Once goods leave the EU, customs formalities apply. According to Ireland's Revenue Commissioners, you'll need to register for customs with an Economic Operators Registration and Identification (EORI) number and submit customs declarations.6 You'll also need the correct Harmonised System (HS) code for your goods. This code determines the import duty rate and any restrictions, while duties and taxes are set by the destination country's authorities. For practical tips, read this customs advice for first-time shippers.

Before you ship, agree Incoterms® (International Commercial Terms) with your buyer. These set out who is responsible for each part of the journey, including who provides the necessary documentation and who pays the duties and taxes. Under FCA (Free Carrier) Incoterms®, for example, you deliver the goods to an agreed named place and handle export clearance, and the costs and risk pass to the buyer from there.

Finally, choose between express and freight. Express shipping suits time-critical pallets within the carrier's weight and size limits, while freight forwarding is better suited to full-container or oversized loads. 

 

DHL Express international pallet shipping

DHL Heavy Weight Express is designed for palletised and heavy shipments, combining the speed of express delivery with the capacity for larger loads. Here's what a DHL Express pallet shipment can take.

DHL Heavy Weight Express handles shipments from 50 kg up to 3,000 kg, with individual pallet pieces of up to 1,000 kg. Pallets can measure up to 300 × 200 × 160 cm, and DHL Express asks for any piece over 70 kg to travel on a pallet. Shipments can reach their destination in as little as one to three days.

Customs clearance and door-to-door delivery are included in the price, while duties and taxes are charged separately. That means DHL Express international pallet shipping covers the whole journey.

 

Pallet shipping checklist before collection

A final check before collection can save time, money, and stress. Run through this list once your pallet is ready:

• Pallet is in good condition, with the ISPM-15 mark visible on wooden pallets leaving the EU.

• Load sits within the pallet footprint, with heavy boxes at the bottom.

• Corner boards are fitted, and straps and wrap are tight.

• Stackability is declared correctly.

• Dimensions and weight are measured, including the pallet.

• Labels are on all sides and the top, with barcodes clear of the wrap.

• Handling labels and pallet numbers ('1 of 3') are in place.

• Documents are in a pouch on the pallet and match your booking details.

• Photos are taken from several angles.

• Pallet is fully prepared and accessible for loading when the courier arrives.

If you ever need to make a claim, photos show how well your pallet was packed. That matters, as shipping insurance typically excludes damage caused by unsuitable packing. Learn more in this quick guide to shipping insurance.

Ship your pallets overseas with DHL Express

A well-packed, correctly declared pallet moves faster, arrives safely, and costs less. With the right preparation, pallet shipping can become a smooth, reliable part of growing your business overseas.

Ready to get started? Apply for a DHL Express business account or request a quote.