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Think a pallet is just a platform? Try moving 100 cases of beer 500 miles without a single tray slipping, bending, or leaking.
From crushed corners to leaked kegs, the wrong beer pallet quietly costs you—on freight, stability, and shelf-ready stock. In this guide, we’ll break down beer pallet dimensions, loading tips, and pallet structures that actually work in real distribution.
What Are the Standard Beer Pallet Dimensions?
Not all beer pallets are 48″ x 40″.
48″ x 40″ (1219mm x 1016mm) is standard in North America, but it’s not the only option.
If you’re shipping internationally or using non-standard kegs, that size might not stack safely, fit export racks, or load efficiently in containers.
Beer pallet dimensions vary by country and shipping method:
- Europe Beer Pallet: 1200×800mm (Euro pallet) for warehouse racking
- Australia Beer Pallet: 1165×1165mm for block stacking
- Asia/Export Beer Pallet: 1100×1100mm, fits tightly in containers
If you’re using odd-shaped kegs, shrink-wrapped trays, or need automation compatibility, custom pallet sizes may be the better call. We help brewers match pallet specs to export markets, storage layouts, and loading plans—for better efficiency and fewer surprises.
How Many Cases of Beer on a Pallet?
Most beer cases hold 24 bottles or cans, each 12 oz. A standard carton for bottles measures around 16″ long × 10″ wide × 10″ high. Cans are similar, slightly more compact.
That means you can fit five cases across the 48-inch side of a standard pallet, and two rows deep on the 40-inch side. So The short answer: about 100 cases per pallet—if you’re using the standard 48″×40″ beer pallet and stacking carefully.
But not all pallets are built the same, and neither are their safe stacking limits. Depending on your pallet size, packaging type, and handling method, the actual case count can shift significantly. Here’s a practical comparison:
48″ × 40″ (North America):
10 cases per layer × 10 layers = ≈100 cases (ideal conditions)
1200 × 800 mm (Euro pallet):
8–9 cases per layer × 8–10 layers = ≈72–90 cases
1165 × 1165 mm (Australia standard):
10–11 cases per layer × 9–10 layers = ≈90–110 cases
1100 × 1100 mm (Asia/export pallet):
9–10 cases per layer × 9–10 layers = ≈85–100 cases
Choosing the Right Pallet for Beer Transportation
In beer logistics, we usually recommend plastic pallets over wood—especially when you’re dealing with moisture, heavy kegs, or long-haul shipping.
Plastic beer pallets don’t absorb water, don’t warp under pressure, and offer more control over surface texture and reinforcement. This helps reduce carton movement during transit, which is critical if you’re stacking high or using shrink-wrapped trays. Compared to wood, plastic performs more consistently across all stages of the supply chain.
Here’s how plastic and wood beer pallets compare in real-world transport conditions:
- Water resistance: Plastic pallets stay dry in humid, wet, or refrigerated environments. Wood absorbs moisture and weakens.
- Load stability: Plastic decks can be molded with anti-slip ribs and lips. Wood often lacks edge control, leading to more movement.
- Weight tolerance: Reinforced plastic options handle keg weight without bending. Wood bases may sag or crack under repeated stress.
- Surface uniformity: Plastic pallets are dimensionally consistent, ideal for automation. Wood varies in size and may splinter.
- Lifespan: Plastic lasts longer, especially in reuse-heavy operations. Wood may require frequent replacement due to breakage.
If you’re running export shipments, stacking kegs, or loading in high-humidity zones, our beer plastic pallets offer the reliability wood can’t match. We help clients align pallet specs with loading plans—not just for stacking more, but for arriving with less damage.
Pallet Structure Matters: Features That Improve Transport Safety
Loads don’t just need to fit—they need to survive forklifts, conveyors, and long-haul bumps. The wrong pallet structure can turn a good shipment into costly damage. Whether you’re moving shrink-wrapped trays or heavy kegs, choosing the right base matters.
Here’s Common Beer Pallet Structures Compared:
| Pallet Structure | Key Features | Best For | Our Design Advantages |
|---|---|---|---|
| Closed-Deck with Anti-Slip Ribs | Sealed top with molded ribs for grip; optional vented surface to prevent pooling | Shrink-wrapped beer trays; cold/humid storage environments | Prevents slippage and carton collapse better than flat wooden decks |
| 3-Runner Base | Three longitudinal runners; reinforced for forklift entry and weight distribution | Heavy loads like kegs; long-haul shipping | Minimizes bending under load; stable for automated fork operations |
| Reversible Double-Deck Pallet | Two full decks with equal load-bearing capacity | High racking systems; two-way stacking; automation | Balanced strength on both sides; ideal for rotation and warehouse efficiency |
| Single-Faced Pallet | Deck on top only; lighter and cost-effective | One-way transport; limited warehouse space | Lower cost for export use; customizable for stackability and volume efficiency |
| Vented/Open Deck Pallet | Grid or slotted surface; improved airflow and drainage | Cold chain beer distribution; wet-fill lines | Reduces moisture buildup; suitable for refrigerated or washable environments |
You can see one example below — a reversible plastic pallet used in a beverage canning line. Its reinforced base handles speed, weight, and automation—just what modern beer logistics demand.
Optimize Your Beer Pallet Loading for Cost-Efficiency
Packing too much—or too little—can both hurt your shipping budget. The key is balancing weight, volume, and carton stability, especially when mixing kegs and cases.
Keg and case load planning is not the same.
A pallet of 24-pack bottles can weigh over 2,000 lbs, but five full kegs reach that weight faster. In mixed loads, kegs should go bottom-center for balance. Stack cartons on top or around to prevent tip-over in motion.
LTL shipments need tighter load control.
In less-than-truckload (LTL) moves, frequent transfers mean more shaking. Shrink-wrapped trays stacked too high often buckle at the base. You should:
- Keep stack height under 6 layers unless boxes are reinforced
- Test carton corners for compression before wrapping
- Press the top layer gently—if it flexes inward, reduce the stack
Overstacking wastes money in TL too.
A truckload (TL) may allow taller stacks, but bottle cartons deform if overcompressed. Pallet deck flex adds 1–2 inches of sag—this risks top-layer collapse during braking or ramp unloading.
Quick checks before loading:
- Weigh the full pallet (with plastic base) to check axle compliance
- Measure total height vs. trailer clearance
- Push the wrapped load from the side—if it wobbles, rework it
Smart stacking protects profit.
You don’t need the “most loaded” pallet—you need the most stable one that survives the route. Better to ship 90 safe cases than lose 10 to crush and leakage.
Do You Need Custom Pallets for Your Brewery?
As a plastic pallet manufacturer, we build around your operation—not assumptions. Poor fit causes slipped kegs, damaged cartons, or automation failures. Our custom molds support:
- Special dimensions for odd-size kegs
- Fork entry designs for tight spaces
- Closed or vented decks for humid or chilled zones
- Custom logos, barcodes, and RFID for traceability
We help you optimize both fit and cost, not overpay for “standard” features you don’t need.
Not sure if you need a custom pallet? Let’s talk.
Share your load type, stacking setup, or storage environment. We’ll recommend a fit-for-purpose pallet—durable, cost-efficient, and ready to ship worldwide.
👉 Request a quote or consultation now.
Want to calculate standard box loads across pallet sizes? Check this guide on how many boxes fit on a pallet.
