A Complete Guide to Palletizing

Everything you need to know before shipping frozen products between South African cities

When your frozen goods travel between Johannesburg, Cape Town, and Durban, they move through a chain of handlers, forklifts, and vehicles before reaching their destination. How you palletize determines whether your products arrive intact—and whether you’re covered if something goes wrong.

This guide explains the specifications that long-haul carriers require, why each requirement exists, and what happens to your insurance claim when you don’t comply.

Why Palletization Matters for Frozen Goods

Frozen products face unique challenges in transit:

• Thermal mass works for you—until it doesn’t. A properly loaded pallet of frozen goods maintains temperature through thermal inertia. But gaps in loading create air channels that accelerate warming. Poor stacking concentrates weight on products not designed to bear it, causing crush damage that only becomes visible after thawing.
• Handling is rougher than you imagine. Your pallet will be moved by forklift at least four times: onto the truck, off the truck at a cross-dock, onto another truck, and off again at destination. Each transfer involves acceleration, braking, and the occasional bump. What seems stable in your cold store may not survive 1,200 kilometres of road vibration plus multiple handling events.
• Claims require compliance. Goods-in-transit (GIT) insurance isn’t automatic protection—it’s conditional coverage. Carriers specify palletization requirements precisely because non-compliant loads cause damage. When your pallet doesn’t meet specifications, you’ve voided the conditions that make claims possible.

The Basics: Dimensions, Weight, and Pallet Type

Pallet Dimensions

Why These Dimensions?

Trailer interiors are designed around standard pallets. A 1m × 1.2m footprint allows efficient loading patterns that maximize payload while maintaining stability. The 1.8m height limit accommodates double-stacking in warehouses and ensures pallets clear trailer roofs with margin for load shift.

Exceed these dimensions and your pallet becomes an obstacle that handlers must work around—increasing damage risk to your goods and everything near them.

Weight Limits by Route

Weight limits vary by corridor:

Route	Maximum Gross Weight per Pallet
Johannesburg ↔ Cape Town	940 kg
Johannesburg ↔ Durban	840 kg
Other routes	Confirm with carrier (typically 850 kg)

Important: The first and last six pallets in a full truck load often have lower limits (850 kg maximum) regardless of route. This relates to load distribution—trailers need balanced weight across axles, and the pallets at each end affect this balance disproportionately.

Why Different Routes Have Different Limits?

The Johannesburg-Durban corridor includes significant gradients and tighter curves than the N1 to Cape Town. Road conditions, axle weight regulations, and the specific vehicles operating each route all influence what carriers can safely transport. The 840 kg limit on the Durban route isn’t arbitrary—it reflects operational reality.

Understanding What’s Law vs Carrier Requirements

It’s worth understanding what’s legally mandated versus what carriers require operationally. The National Road Traffic Act (NRTA) regulates vehicle-level constraints: maximum axle loads (9,000 kg per single axle, 18,000 kg for tandem units), gross combination mass (56,000 kg maximum), vehicle dimensions (4.3m height, 2.7m width), and the bridge formula for axle spacing. SANRAL operates weighbridges on major routes—the N3 Heidelberg Traffic Control Centre is a compulsory stop for all heavy vehicles, checking both total mass and individual axle compliance.

What the law doesn’t regulate: pallet weights, cargo spacing within trailers, or pallet configurations. The 940 kg and 840 kg per-pallet limits are carrier operational requirements, not legal mandates. Carriers set these limits to ensure they can load trailers efficiently while staying within legal axle limits across different vehicle configurations and route conditions. Similarly, the “first and last six pallets” restriction relates to trailer load distribution for axle weight compliance—carriers have worked out what configurations keep them legal at weighbridges.

This distinction matters for claims: exceeding carrier specifications voids your GIT coverage even though you haven’t broken any law. The carrier’s operational requirements exist precisely because they’ve calculated what keeps shipments legal, safe, and insurable.

Exceeding weight limits:

• Attracts surcharges (typically R3-4 per kilogram over limit)
• Voids GIT insurance coverage
• May result in refused loading

Pallet Type

Use standard South African wooden pallets in good condition. Check for:

• No broken or missing deck boards
• Intact stringers (the structural blocks between deck layers)
• No protruding nails
• No rot or significant damage

Plastic pallets with plastic crates: This combination creates a slippage hazard. Plastic-on-plastic has low friction, meaning your carefully stacked crates can slide during transit, causing lean, collapse, or product damage. If you must use plastic crates, wooden pallets provide the friction needed for stability.

Loading Your Pallet

How you arrange products on the pallet matters as much as what you’re shipping.

Edge-to-Edge Loading

Weight Distribution

The bottom layer carries everything. Whatever you place at the bottom must support the entire pallet weight through 1,200+ kilometres of road vibration and multiple handling events.

• Place heaviest, most durable cartons at the bottom
• Never stack fragile products under dense ones
• If using mixed products, plan your layers by structural capacity, not just convenience

Double-stacking considerations: When carriers double-stack pallets in the trailer, your bottom pallet’s top layer must support the pallet above. This effectively means your upper layers need to handle an additional 500-900 kg. Plan accordingly.

Flexible Packaging

Bags, pouches, and other flexible packaging sag and settle during transit. What fits perfectly at loading may bulge beyond pallet edges after 12 hours on the road.

• Allow 20-30mm margin from pallet edges for flexible products
• Expect bags to compress and spread under their own weight
• Shrink-wrap tightly to contain settlement

Securing Your Pallet: Shrink-Wrap Specifications

Shrink-wrap isn’t just about keeping things tidy—it’s structural. Properly wrapped pallets become unified masses that resist the forces of transit. Poorly wrapped pallets become loose collections of products waiting to fail.

Coverage Requirements

Wrap must cover:

• All four sides: Complete coverage from pallet deck to top of load
• The top: Either overwrap or hood-style coverage that seals the top surface

Partial wrapping—sides only, or wrap that stops short of the top—doesn’t meet carrier requirements.

What “Properly Wrapped” Means

Why This Matters for Claims

Intact shrink-wrap at delivery = no shortage claims accepted.

This seems harsh, but the logic is sound: if the wrap is intact and the seal hasn’t been broken, products couldn’t have left the pallet during transit. Any shortage existed before shipping.

Poor shrink-wrap = no damage claims accepted.

If your wrap was inadequate and products shifted or fell during transit, the damage resulted from your preparation, not carrier handling.

Carriers document pallet condition at pickup. If they note poor wrap or visible damage, you’ve already compromised your claims position.

Labeling: What Goes Where

Every pallet needs identification on all four sides. Not one side. Not two sides. All four.

Temperature Marking

Clearly state the required temperature regime:

Product Type	Label Marking
Frozen	FROZEN: -18°C
Chilled	CHILLED: +4°C
Ambient	DRY: NO TEMPERATURE

Use large, clear text that’s visible from a distance. Handlers sorting dozens of pallets in a cross-dock shouldn’t need to peer closely to identify your temperature requirements.

Carrier-Specific Labels

Some carriers provide their own labels or require specific formats. Ask your carrier or logistics coordinator about requirements for your route. Using incorrect labels can delay shipments or cause pallets to be set aside for clarification.

What Voids Your Coverage

GIT insurance provides financial protection when carriers damage or lose your goods—but only when you’ve met your obligations. The following conditions void coverage:

Dimensional non-compliance:

• Pallet height exceeds 1.8 metres (including pallet)
• Products overhang pallet edges
• Non-standard pallet dimensions

Weight non-compliance:

• Exceeds route-specific weight limit
• Exceeds position-specific limit (first/last 6 pallets)

Packaging failures:

• Inadequate shrink-wrap coverage
• Shrink-wrap not secured top and sides
• Poor wrap allowing product movement

Pallet condition:

• Damaged or broken wooden pallets
• Plastic pallets used with plastic crates
• Pallets unsuitable for the load weight

Labeling failures:

• Missing labels (must be on all 4 sides)
• Missing temperature requirements
• Illegible or damaged labels

Pre-existing issues:

• Damage visible at pickup
• Products already compromised before shipping

When your shipment doesn’t meet specifications, carriers may still transport it—often with documented exceptions and surcharges—but you’re shipping at your own risk.

Our Role: Palletization Services from The Frozen Food Courier

We understand that not every business has the facilities, equipment, or expertise to palletize goods to long-haul specifications. That’s why we offer palletization as a service.

What We Provide

• Proper palletization: We load your products onto standard wooden pallets following all carrier specifications—correct dimensions, weight distribution, and edge-to-edge loading.
• Professional shrink-wrapping: Full coverage meeting carrier requirements, tight enough to stabilize loads through 1,200+ kilometres of road travel.
• Compliant labeling: All four sides labeled with your details and correct temperature markings.
• Weight verification: We weigh each pallet to confirm compliance with route-specific limits before handover to long-haul carriers.
• Documentation: Photographic records of pallet condition at handover, supporting your position if claims arise.

When to Use This Service

Consider our palletization service if:

• You’re shipping loose cartons or mixed products
• Your facility lacks palletization equipment
• You’re unsure whether your current palletization meets carrier requirements
• Previous shipments have experienced damage or claims rejection
• You want documentation of pallet condition at the point of carrier handover

How It Works

Contact us before your shipment to discuss volumes and timing. We’ll collect loose goods, palletize to specification at our facility, and coordinate handover to your chosen long-haul carrier. You receive confirmation and photographs once your pallets are in transit.

For details on our palletization services, contact us at hello@thefrozenfoodcourier.co.za.

Quick Reference Checklist

Print this for your warehouse team:

Before Loading

☐ Pallet is standard 1m × 1.2m wooden pallet with four-way entry
☐ Pallet is undamaged (no broken boards, protruding nails, or rot)
☐ If using plastic crates, pallet is wood (not plastic-on-plastic)

Loading

☐ Products loaded edge-to-edge with no gaps
☐ Heaviest/strongest cartons on bottom layer
☐ No products overhanging pallet edges
☐ Total height will not exceed 1.8m including pallet

Weight

☐ Johannesburg ↔ Cape Town: Maximum 940 kg gross
☐ Johannesburg ↔ Durban: Maximum 840 kg gross
☐ Other routes: Confirmed with carrier (default 850 kg)
☐ If first or last 6 pallets in full load: Maximum 850 kg

Wrapping

☐ Shrink-wrap covers all four sides completely
☐ Shrink-wrap covers top of load
☐ Wrap is tight—products don’t shift when pushed
☐ No tears, gaps, or loose sections

Labeling

☐ Labels applied to all four sides
☐ Company name, contact person, phone, email on each label
☐ Temperature requirement clearly marked (FROZEN: -18°C / CHILLED: +4°C / DRY)
☐ Carrier-specific labels applied if required

Final Check

☐ Pallet appears stable and professional
☐ No visible damage to products or packaging
☐ Weight verified against route limit
☐ Photographs taken for records

Global Pallet Standards: A Quick Reference

If you’re importing products or exporting to international markets, you’ll encounter different pallet standards. Here’s how South African practice fits into the global picture.

The Major Standards

Standard	Dimensions	Primary Region	Governing Body
Euro Pallet (EUR/EPAL)	800 × 1200 mm	Europe	European Pallet Association
ISO 1 / South African Standard	1000 × 1200 mm	South Africa, UK, Europe, Asia	ISO 6780
GMA Pallet	1016 × 1219 mm (40″ × 48″)	North America	Grocery Manufacturers Association
Australian Standard	1165 × 1165 mm	Australia	Australian Standard
Asian Standard	1100 × 1100 mm	Japan, Korea	JIS

South Africa’s Position

South Africa uses the 1000 × 1200 mm pallet (ISO 2 equivalent), which aligns with UK and broader Commonwealth practice. This is slightly larger than the European EUR 1 pallet (800 × 1200 mm) but close to the North American GMA standard.

Why this matters for cold chain:

• Container loading patterns differ between standards
• A 20-foot container fits 10 South African pallets or 11 Euro pallets
• Import shipments may arrive on different pallet sizes requiring re-palletization
• Export customers may specify pallet standards in their requirements

ATP: The International Cold Chain Standard

The Agreement on the International Carriage of Perishable Foodstuffs (ATP) is a United Nations treaty governing refrigerated transport between signatory countries. Key points:

• 50 signatory states, primarily in Europe and Central Asia
• South Africa is not a signatory—ATP certification is not legally required for domestic transport
• Covers vehicle certification (insulation coefficient, refrigeration capacity), not cargo configuration
• Required for cross-border transport into ATP-signatory countries
• Temperature classes: Class A (+7°C), Class B (-10°C), Class C (-20°C)

If you’re exporting temperature-controlled goods to Europe, your transport equipment may need ATP certification for the final leg. South African domestic transport is governed by R638 food safety regulations, not ATP.

Pallet Height and Weight: No Global Standard

While pallet footprint dimensions are standardised, maximum pallet height and weight vary by carrier, route, and handling infrastructure—not by international standard.

Region	Typical Max Height	Typical Max Weight	Notes
Europe	1.8 m	1,000-1,500 kg	EPAL rates 1,500 kg safe working load
North America	1.8-2.0 m	1,134 kg (2,500 lbs)	Varies by retailer specification
South Africa	1.8 m	840-940 kg	Carrier-specific, route-dependent
Australia	1.8 m	1,000 kg	Standard racking compatibility

The South African limits (840-940 kg per pallet) are conservative compared to international norms—driven by our vehicle configurations, axle weight regulations, and route conditions rather than pallet structural capacity.

ISPM 15: The Phytosanitary Requirement

Any solid wood packaging (including pallets) crossing international borders must comply with ISPM 15—the International Standards for Phytosanitary Measures. This requires:

• Heat treatment (56°C core temperature for 30 minutes) OR
• Methyl bromide fumigation
• Official stamp with treatment mark and country code

Non-compliant pallets can be refused at customs, fumigated at your expense, or destroyed. If you’re exporting on wooden pallets, ensure they carry the ISPM 15 stamp.

Questions?

If you’re unsure whether your palletization meets requirements—ask before shipping. It’s easier to fix problems at origin than to fight rejected claims at destination.

Contact: hello@thefrozenfoodcourier.co.za

Related information:

• Our Terms and Conditions (see Section 3.7 and Section 19)
• Our Service Partners