How should polystyrene boxes be arranged on a pallet?

Keeping boxes within the pallet footprint is only the start. Bottom-layer pressure, alignment, interlayers and stretch tension need joint control.

30 March 2026Updated 28 September 2026

Short answer

Place the polystyrene boxes inside the pallet footprint so the bases press evenly and the layers stay aligned, and do not let stretch film or strapping pull the corners inward. The real test is a pallet built with the actual shipment load, not empty boxes: inspect it from four sides and change the pattern if you see crushing, overhang or film pressure.

Because a polystyrene box is light, palletising looks easy; the trouble comes from sliding, overhang and stretch film crushing the box rather than from weight. Test the pattern with the real load, because a trial with empty boxes does not represent a full pallet.

Boxes stay inside the pallet footprint, leave no wide channels between them and press on the pallet with balanced bases; mixing different base sizes in one column creates point loads.
Lids sit flat and layers are aligned; if an interlayer is needed it is chosen for humidity and temperature, and no heavy carton goes on an upper layer before the box's load capacity is known.
Stretch film or strapping does not pull the corners inward; corner protectors and tension are tried on a loaded pallet.

Sources and correction policy for this article

Topics:Warehouse and dispatch Risk and emergencies Single-use packaging

Cold chain logistics →Isotec guide hub →What the cold chain is →