Shipping a pallet: groupage network or direct drive?
There are two ways to move a pallet. In a groupage (LTL) network, a local vehicle collects the pallet, it is cross-docked at a depot, often routed through a hub and delivered by the destination depot. Pricing there is usually based on weight, number of pallets or loading metres and distance; one euro pallet equals 0.4 loading metres. On a direct drive, one vehicle carries only your load from pickup to recipient, and the price depends on distance and vehicle class.
Groupage is usually cheaper when a single, stackable euro pallet travels a long distance with no fixed deadline and there is a forklift or loading dock at both ends. The direct drive pays off when the pallet has to arrive the same day, carries fragile or non-stackable goods, the recipient has no dock, or several pallets on a short route fit into one vehicle.
One point that is often overlooked: every cross-dock means the pallet is moved by forklift again and set down next to other people's freight. For glass, electronics or tall stacks of cartons that is an extra damage risk – and it does not exist on a direct drive.
Pallet types and sizes: euro pallet, industrial pallet, mesh box
The EPAL euro pallet measures 1,200 × 800 mm and is 144 mm high, weighs around 25 kg and, according to EPAL, carries up to 1,500 kg. The EPAL 3 pallet, often called the industrial pallet, measures 1,200 × 1,000 mm, weighs around 30 kg and also carries 1,500 kg. The half pallet (EPAL 6) is 800 × 600 mm and carries up to 750 kg.
The EPAL mesh box pallet has internal dimensions of 1,200 × 800 mm, is 970 mm high, weighs around 70 kg empty and carries up to 1,500 kg. Its tare weight is easy to forget: four mesh boxes put almost 300 kg on the scales before any goods go in.
One-way pallets have no standard size and belong to no exchange pool. Measure them and state the actual footprint – a one-way pallet of 1,200 × 1,000 mm takes up more space than a euro pallet.
For choosing the vehicle, gross weight is what counts: goods, packaging and pallet together. The loading metre calculator shows how many pallet spaces a vehicle offers, and the payload calculator checks whether the weight fits.
Packing a pallet properly: stacking, wrapping, labelling
Legally, securing the goods on the pallet is the sender's job: under Section 411 of the German Commercial Code (HGB), the sender must stow and secure the goods on the load carrier so they are safe for transport. The carrier does not have to pay for damage caused by inadequate packaging (Section 427 HGB).
In practice that means heavy items at the bottom, cartons stacked in an interlocking pattern and nothing overhanging the edge of the pallet. If goods overhang, the size of the load counts, and the overhanging edge is the first thing to hit the side of the vehicle during loading. Run the stretch film around the pallet itself at the bottom so that load and pallet form one unit; the German guideline VDI 3968 Part 5 describes how load units are stretch-wrapped. For heavy or sharp-edged goods, add strapping with edge protectors.
Label every pallet on two sides with the recipient, number of packages and notes such as "do not stack" or "this way up". Put the delivery note in a pouch on the outside of the film and photograph the finished pallet before collection. On a Maxmove direct drive, the digital proof of delivery records the handover with photo, signature and timestamp – so the condition is documented at both ends.
How high and how heavy can the pallet be?
The limit is usually set by the vehicle, not the pallet. A euro pallet carries 1,500 kg – more than the up to 1,200 kg a 3.5 t box truck may carry in total. What matters is internal height and booked payload: in a van with a 2.6 m load length the ceiling is at around 1.35 m, in a Sprinter L2 at around 1.80 m and in a 3.5 t box truck at around 2.10 m. Measure the total height including the pallet (144 mm) and the film.
For weight, everything that goes on the load floor counts. An example: four euro pallets with 250 kg of goods each weigh around 1,100 kg including the pallets. That is too much for a Sprinter L2 with up to 1,000 kg of booked payload; the 3.5 t box truck with up to 1,200 kg fits.
If you are close to a limit, do not guess: if the load does not fit the booked class, the run cannot go ahead as planned. Enter the height and gross weight per pallet when you book and choose the vehicle class accordingly. Pallet loads over 1.2 t can be booked in the 7.5 t truck with up to 3,000 kg of payload and 12 to 15 euro pallets. Loads over 3 t, on an open flatbed or with crane unloading run as a special transport on request.
Pallet exchange and euro pallet deposit: what actually applies
There is no deposit for euro pallets set by law. What people call a "deposit" is the value of an exchangeable pallet that sender, recipient or forwarder charge each other when pallets are not swapped on the spot. Whether pallets are exchanged and at what value is purely a matter of contract. The German forwarders' terms ADSp 2017 make this explicit: unless expressly agreed, an order covers neither the provision nor the exchange of pallets (clause 4.8.1).
An EPAL euro pallet only counts as exchangeable if it has none of the defects listed in EPAL's exchange criteria: no board or block may be missing, no board may be broken across or diagonally, and no twisted block may protrude by more than 10 mm. The quality classes A, B and C for used pallets are a recommendation and only apply if both sides agree to them.
For your direct drive this means: pallet exchange is not automatically part of the run. Agree with the recipient beforehand whether they will hand back empty pallets, and record the number and condition on a pallet note. If you do not want to exchange at all, ship on one-way pallets.
The details your driver needs for a pallet shipment
Most delays in pallet shipping happen at the loading dock, not on the road. With these details in the booking, the right vehicle turns up with the right equipment:
Number and type of pallets (euro, industrial, mesh box, one-way), total height and gross weight per pallet, and whether they can be stacked.
Loading equipment at both ends: forklift, dock, pallet truck or none of these. Without a dock and forklift you need a vehicle with a tail lift and pallet truck – you select that when you book.
Access and handover: gate, hall, gate times and a phone number on site. Plants and distribution centres with gatehouse registration often ask for a reference or order number; add it in the notes field.
Paperwork: delivery note on the pallet and, if needed, a pallet note for the exchange.
If you run the same routes regularly, for example between warehouse and branch, recurring pallet runs can be set up as fixed orders – talk to us via the business account.