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A Guide for Best Practices for Storing Pallets

Updated: May 28

Keeping people safe while you manage your logistics

Storing wooden pallets

Managing warehouse space efficiently is crucial for maintaining productivity and safety, particularly when it comes to storing pallets. Whether you're storing empty pallets or looking for effective ways to manage loaded pallet storage systems, our guide will help ensure that you adopt the best practices. 

Below, we answer some common questions about storing pallets and provide strategies to maximise your storage space and efficiency. If you want to get in touch with any questions about pallets, feel free to reach out to the Born Again Pallets team.

What are the best practices for storing empty pallets?

Storing empty pallets efficiently is key to maintaining an organised warehouse. The best practice is to stack empty pallets neatly in a designated area. Ensure that stacks are not too high to prevent toppling—generally, keeping stacks around two metres or lower is advisable. 

Additionally, inspect pallets regularly for any damage and remove broken ones from the stack to ensure safety and maintain quality.

Warehouse pallet storage solutions

What are the best practices for storing loaded pallets to ensure stability and accessibility?

When storing loaded pallets, it is crucial to adhere to best practices that ensure both the stability of the pallet stacks and accessibility to the items stored. 

Follow these steps to keep yourself and your employees safe:

  1. Firstly, always check that the weight on the pallets is evenly distributed, with heavier items at the bottom to prevent toppling and ensure the stack's stability. 

  2. Use pallets that are in good condition, without any damage that could compromise their structural integrity under load. 

  3. Organise the warehouse layout to ensure that the most frequently accessed items are stored in a manner that they can be easily reached, ideally in lower or outer positions.

  4. Arranging and organising removes the need for frequent restacking and reduces the risk of accidents. 

  5. Maintain clear aisles and sufficient space around stacked pallets to facilitate safe and efficient movement of personnel and forklifts. 

Implementing these practices not only helps in maintaining an organised warehouse but also significantly enhances operational safety and efficiency.

How should you store pallets on pallet racks?

Pallet rack storage systems are designed to maximise vertical space while ensuring easy access to stored goods. Here are some things to consider:

Weight distribution

Place heavier loads on the lower shelves and lighter ones above. This lowers the centre of gravity and significantly reduces the risk of the racks tipping over.

Proper fit

Ensure that pallets fit well within the racking dimensions without overhanging, as this can lead to accidents or damage to the stored goods. Each pallet should be placed squarely on the beams, with sufficient clearance from adjacent pallets and rack frames.


It's important to consider the height of stacked pallets. Make sure that the height of the stacked goods does not exceed the maximum loading height recommended for your specific racking system.


While maximising vertical space is efficient, accessibility should not be compromised. Arrange goods in a way that the items needed most frequently are the easiest to access. This might mean positioning such items at the front of the racks or at a height that does not require assistance.

Regular inspections and maintenance

Regularly inspect your pallet racks for any signs of damage or wear, such as dents, rust, or bent beams and uprights. Damaged components can compromise the structural integrity of the racking system and pose serious safety risks. See more about this below.

Proper implementation of these practices will help prevent workplace accidents, improve accessibility, and extend the life of your storage equipment. By adhering to these guidelines, you can ensure that your pallet racking system is not only efficient but also safe and compliant with industry standards.

Can you suggest some innovative pallet storage ideas?

For those looking to enhance their storage setups, exploring innovative pallet storage ideas can be beneficial. Innovative storage solutions include:

  • Vertical storage solutions employ stacking frames and over-dock storage to maximise vertical space and improve storage density.

  • Implementing mobile shelving on tracks can reduce aisle space and increase storage density for less frequently accessed items.

  • Modular pallet racking with adjustable shelving and removable panels in racking systems for flexible and customisable storage configurations.

  • Adopt gravity flow racks for efficient FIFO inventory management, reducing labour for moving products.

  • Designate high throughput zones near dispatch areas for frequently accessed items and bulk storage zones for larger, less frequently accessed inventory.

  • Integrate mezzanines or raised platforms to allow for manual picking on upper levels and bulk storage below.

  • Automated Storage and Retrieval Systems (ASRS) can enhance storage density, reduce labour costs, and improve inventory management efficiency.

  • Implement portable, adjustable docking points to accommodate various pallet and cargo sizes, streamlining the loading and unloading process.

How do you manage pallet wood storage?

Pallet wood storage requires attention to detail to prevent damage and decay. Store pallets off the ground, preferably on racking that allows for airflow around and beneath the pallets to keep the wood dry and prevent rot. 

For outdoor storage, cover pallets with a waterproof tarp to protect them from the elements. Regularly check and treat wood pallets to protect against pests and moisture.

How do you ensure safety with pallet racking storage?

Ensuring safety in pallet storage is crucial and involves several key precautions:

Regular inspections

Conduct routine inspections of pallets and racking systems for any signs of damage or wear. Do this as often as you can, at least once per quarter. It even pays to inspect each individual pallet as it arrives at your warehouse.

Load limits

Strictly adhere to the manufacturer’s load recommendations to avoid overloading. Overloading can lead to injury and potentially even death. It’s never worth loading pallets to make them too heavy or too tall.

Proper training

Ensure all staff are trained on the correct procedures for stacking and handling pallets. Make sure that only trained forklift and pallet jack operators are using the equipment that they are qualified to use.

Safety equipment

Install safety barriers, rack guards, and other protective equipment to prevent accidents. Ensure that all staff are trained in using safety equipment, and are adhering to general workplace health and safety requirements, such as wearing high visibility clothing.

Ensure regular inspections of existing and new pallets

How can Born Again Pallets help your business implement best practices for pallet storage?

Implementing best practices for storing pallets is essential for maintaining a safe and efficient warehouse environment. By choosing the right pallet solutions and adhering to safety standards, businesses can optimise their operations and prevent costly accidents. Born Again Pallets is committed to providing high-quality pallet solutions and expert advice to help businesses in Australia and beyond achieve their logistic goals from recycling pallets to shipping. solution. Contact us to choose the right pallet to meet your storage needs.

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