Standard Pallet Sizes

The 48 x 40 pallet is the most common pallet size used in U.S. warehousing. It is widely used for grocery, retail, consumer packaged goods, and general freight because it fits efficiently inside standard trailers and works well with most warehouse handling systems.

But 48 x 40 is only one of several pallet sizes that regularly show up on Georgia loading docks. Depending on your product, industry, load weight, and trailer space, a standard pallet may not always be the most cost-effective option.

Here's a breakdown of the pallet sizes used most often, what they're commonly used for, and how to know when a custom pallet may save you more money than a standard one.

The standards you'll see most often

These four sizes cover a large share of domestic freight in the U.S.:

• 48 x 40 — The grocery and CPG default. This size is built to fit two-wide in a 96-inch trailer and is commonly used for consumer goods, retail distribution centers, and general warehousing.
• 48 x 48 — The drum pallet. This square pallet is commonly used to hold four 55-gallon drums in a 2x2 footprint without overhang. It is often used in industrial chemicals, lubricants, and process manufacturing.
• 42 x 42 — Common in telecom, paint, beverage, and specialty shipping applications. Its square footprint can work well for certain conveyor systems and product layouts.
• 36 x 36 — Often used for masonry, brick, and heavy compact loads. These pallets are typically built stronger to support dense products without unnecessary extra lumber.

The sizes Georgia industry depends on

These sizes may not be standard pool pallets, but they are common across specific industries in Georgia. We build these regularly for customers across Cobb County and surrounding areas:

• 96 x 40 and 96 x 48 — Long-format pallets used for flooring rolls, cabinet panels, fencing, building materials, and other oversized products. These are especially common in industries tied to flooring, cabinetry, and building supply.
• 72 x 48 — A practical middle-ground size for cabinet shops, building suppliers, and manufacturers whose products are too long for a 48 x 48 pallet but do not require a full 96-inch pallet.
• 45 x 45 and 46 x 46 — Tighter drum footprints used when a 48 x 48 pallet takes up more trailer space than necessary. These can provide similar load stability while helping reduce wasted freight space.
• 32 x 32 — Compact pallets for smaller custom loads where a 48 x 40 pallet wastes space, increases freight cost, or creates handling inefficiencies.

How to tell when you've outgrown the standard pallet

A 48 x 40 pallet may look cheaper on a per-pallet basis, but it can become expensive when it does not match your product or shipping process.

1. Your product overhangs the pallet. Overhang can lead to load instability, product damage, returned shipments, and freight claims. In many cases, a custom-sized pallet can pay for itself by preventing a single damaged load.
2. You're wasting trailer space. If your boxes or products do not fit the 48 x 40 footprint efficiently, you may be shipping air. A custom pallet sized around your product dimensions can help you fit more product per trailer.
3. Your team is double-handling loads. If operators have to reposition, restack, or adjust loads because the pallet does not match the product, the issue may not be labor — it may be the pallet design. The right size and deck-board layout can make handling faster and cleaner.
4. Your loads are heavier than standard pallets are designed to handle. Heavy industrial loads may require stronger stringers, closer deck-board spacing, or a custom build designed around the actual weight and handling requirements.

New Wood Pallets, Mixed Load Pallets, and Recycled Pallets

Within standard sizes, pallets are often described by condition and build quality:

• New Wood Pallets — Built from new lumber and commonly required for food-grade, pharmaceutical, export, or receiver-specific applications.
• Mixed Load Pallets — Repaired or recycled pallets that may include companion stringers, plugs, or mixed components. These are structurally sound for many shipments but may not have the appearance of a new pallet.
• Recycled Pallets — Previously used pallets that have been inspected, repaired when needed, and put back into service. These can be a cost-effective option for many general shipping needs.

When to call us

If you're a warehouse manager, shipping coordinator, or operations lead in North Georgia and you're not sure whether standard or custom pallets make more sense, we can walk through your load profile with you.

We build custom pallets for masonry suppliers, flooring distributors, drum operations, building supply companies, food-grade facilities, and manufacturers across Cobb County and surrounding areas. We'll help you determine whether a standard pallet will do the job or whether a custom build could reduce damage, improve handling, and save money on freight.

Related reading: How to spec a custom pallet · How many pallets fit on a truck · Custom pallet sizes we build