Definition
A flat board, frame, or layer placed between stacked palletized loads to distribute weight evenly and protect the products below. Pallet spacers prevent the bottom deck boards or legs of the upper pallet from creating point loads on the products of the lower pallet. They are especially important when stacking loads with uneven or fragile top surfaces. Spacers may be made from plywood, corrugated board, or plastic.
Related Terms
Stacking Strength
The maximum weight that can be safely placed on top of a loaded pallet or palletized unit load without causing damage to the products or pallet below. Stacking strength depends on the pallet's structural design, the compressive strength of the products, and the stability of the load configuration. Edge boards, top caps, and interlocked stacking patterns all contribute to increased stacking strength. This specification is critical for warehouse floor stacking and container loading.
Top Cap
A flat sheet of corrugated board, plastic, or plywood placed on top of a palletized load before wrapping or strapping. Top caps distribute downward pressure from stacked loads, protect the top layer of products from dust and moisture, and provide a stable surface for stacking additional pallets on top. They are an inexpensive way to increase the stacking strength of a unit load and are widely used in distribution centers and warehouses.
Dunnage
Loose materials or custom-cut pieces of wood, foam, or other materials placed around and between cargo to prevent damage during storage and transport. In the pallet industry, dunnage refers specifically to wood pieces used to brace, cushion, or separate products on a pallet or inside a shipping container. Like pallets, solid wood dunnage used in international shipping must comply with ISPM-15 requirements.
Unit Load
A quantity of goods assembled and secured on a pallet to form a single handling unit for storage and transportation. The unit load concept is fundamental to modern logistics — by consolidating individual items into pallet-sized units, material handling efficiency is dramatically improved. A well-built unit load is stable, within weight limits for the pallet and handling equipment, and configured to maximize trailer or container space utilization.
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Our glossary contains 165+ terms covering everything from pallet construction to compliance regulations and industry organizations.