The grocery industry uses standard pallet sizes. This helps with handling, storage, and transporting products in the supply chain. Many pallet sizes vary by region, but some have become standard for grocery use. According to Repackify research – there are about two billion pallets in use today, about 80% of these are standard 48×40 wooden pallets.
North American Standard: The GMA Pallet
In North America, the grocery industry mainly uses the 48” x 40” pallet. This is often called the GMA pallet. This standard came from the Grocery Manufacturers Association. It’s now called the Consumer Brands Association. It is the main platform for food and beverage distribution.
The history of the GMA pallet dates back to the early 20th century. In 1908, many grocers in the United States joined forces. They formed the American Specialty Manufacturers of America (ASMA). In the 1940s, the association helped set up the Food and Drug Administration. Then, it changed its name to the Grocery Manufacturers of America (GMA). Soon after, it created the GMA pallet to standardize grocery transportation.
The 48” x 40” GMA pallet accounts for approximately 30% of all new wood pallets produced in the United States. These pallets are specifically designed with grocery handling in mind and typically feature:
- Four-way forklift entry with two notches on each side
- Static load capacity of around 4,000 to 5,000 pounds when stationary
- Dynamic load capacity of around 2,000 to 2,500 pounds when in motion
- Top and bottom deck boards that are a minimum of 1/2 inch thick
- A typical height of 5.6 to 7 inches
- An average weight of about 40 to 50 pounds for wooden versions
Major grocery retailers have standardized around this size. Costco needs 48” x 40” block pallets for all deliveries. No product overhang is allowed. Walmart prefers a 40” x 48” CBA grade-A white wood or pooled pallet.
Half Pallets for Retail Merchandising
Another important format in the grocery industry is the half pallet, which measures 40” x 24”. These pallets serve a specialized purpose within grocery retail:
- Ideal for promotional displays and in-store merchandising
- Better suited for smaller quantity orders
- Reduces distribution and retail labor requirements
- Facilitates retail-ready packaging concepts
- Can support loads up to 1,200 pounds
The CHEP half pallet makes brands shine. It boosts sales and improves product visibility in stores. CHEP’s half pallets provide real benefits in the supply chain. The Little Potato Company switched to these pallets. They saved a lot on packaging costs. They also improved food safety and had almost no damage during tests at 700 stores.
A key innovation in half pallet design is that they can be used directly on the retail floor. You can remove the bottom shelf in that aisle section. Then, use the pallet instead. This cuts down on stocking labor and reduces the chance of product damage.
European Grocery Standards
In Europe, grocery distribution mainly relies on the Euro pallet. It measures 1200mm x 800mm, or about 47.2” x 31.5”. This pallet is standard across European supply chains. Many conveyor systems and handling equipment in Europe are made to fit this size.
The EUR-pallet, or Euro-pallet, comes from wooden pallets used in trains. In 1961, European railways set out to standardize a common pallet type. They did this under the guidance of the UIC. The inventors were Swedish brothers Ivar and Tore Svensson. The Euro-pallet allows loading railway carriages in just 10% of the time it used to take.
The EPAL Euro pallet has very specific standardizations:
- Dimensions: 800mm x 1,200mm x 144mm
- Weight: approximately 25 kg
- Construction: 11 boards, 78 nails, and 9 blocks
- Safe working load: 1,500 kg
- Maximum stacking load on solid surface: 5,500 kg
Over 650 million EPAL pallets are used worldwide. They are the most common exchange pallets, especially in Europe.
Materials and Innovations
Plastic pallets are gaining popularity in the grocery industry. Still, wooden pallets remain common. They have several benefits:
- Improved hygiene, as they don’t absorb bacteria or mold
- Consistent dimensions and weight
- RFID tracking capabilities for real-time shipment monitoring
- Easier cleaning and sanitization
- Lighter plastic pallets usually weigh 15 to 30 pounds. In contrast, wooden pallets weigh between 30 and 70 pounds.
I want to tell you about these plastic pallets from iGPS. They’re 48” x 40” and weigh 48.5 pounds, specifically designed for grocery supply chains. I added RFID tracking for full coverage on the top deck. This helps protect your shipments better. I made them from HDPE (high density polyethylene). They’re really durable and can support up to 2,800 pounds. You can even rack them by the edge without problems.
I’ve also noticed corrugated pallets becoming more popular lately. I make these from layers of cardboard. This keeps them very lightweight, usually weighing between 10 and 20 pounds. They’re not as durable as plastic or wood, but they’re perfect for one-time shipments or short-term use. I find they’re particularly valuable in industries that prioritize cost-effectiveness and recyclability.
Grocery Retailer-Specific Requirements
Major grocery chains often establish their own pallet requirements that suppliers must follow:
Costco Pallet Requirements:
- 48” x 40” block pallets with no product overhang
- Pallets loaded with less than 750 pounds must be able to handle 1500 pounds of bottom layer weight
- Pallets with over 750 pounds need to support 2500 pounds from the bottom layer.
- Total pallet load weight cannot exceed 2500 pounds
- Complete load heights cannot exceed 58 inches, including pallet height
- Accepts block pallets from iGPS, CHEP, and PECO only
Walmart Pallet Requirements:
- 40” x 48” CBA grade-A white wood or pooled pallet
- At least 7 top boards, 5 bottom boards, and 3 stringers
- No missing or broken boards on top or bottom
- Pallets should be clean and odor-free without debris and stains
- No cracks wider than ⅛-inch wide and 15 inches in length
- No splinters greater than three inches in length
- Accepts pallets from iGPS, CHEP, and PECO
Market and Regional Considerations
The wood pallet market is large. It’s estimated to be worth USD 108,155.38 million in 2025. Then, it’s expected to grow to USD 188,206.22 million by 2033. This means a growth rate of 7.17% each year. Regional factors can significantly affect pallet costs. California has some of the highest wooden pallet costs in the country. This is because of the high demand for 48” x 40” pallets and the high cost of living.
The 48” x 40” pallet is now standard in North American grocery supply chains. This has led to big efficiencies. Meanwhile, half pallets are still evolving to meet changing retail needs. PECO checks and repairs its pallets to keep high-quality standards. This helps the grocery supply chain work with safe and reliable pallets.
