Industry Standards for Lifting Pallets with Forklifts: 4-Way vs. 2-Way Pallets

When you store goods in a warehouse, manufacturing facility, or distribution center, you may need to use pallets. By placing items directly on pallets, they can be picked up and transported to another location with forklifts and similar types of material handling equipment. Using pallets in your warehouse makes it easier to store and transport goods.

There are, however, many different pallet materials, sizes, and types to choose from. If you’ve already purchased forklifts for your warehouse, keep in mind that not every forklift can handle all types of pallets.

Make sure you match your forklift with the pallet style you select for your facility. Two of the most common pallet types are 2-way and 4-way pallets, each of which provides numerous benefits for material handling applications. The purpose of this guide is to explore which end of pallet industry standard for lifting pallets forklifts.

Pallet Basics

Pallets are an important aspect of logistics. They are portable and rigid platforms that can carry practically any type of load. Since the platform is flat, it’s easy to stack items for efficient transportation. You can use various types of pallets in your facility to move, store, and pile up goods. Once the pallets are full, they can be moved with pallet jacks or forklifts.

There are many pallet types available, which include expendable and reusable ones. You can also select stackable and reversible pallets. The different materials that pallets are made from include the following:

• Metal
• Lightweight plywood
• Wood
• Presswood
• Corrugated cardboard/paper
• Plastic

GMA-Style Pallet

Most of the pallets that are used in warehouses and distribution centers fit a standard shape and size that’s known as GMA-style, which is based on the Grocery Manufacturers Association (GMA). The GMA created a pallet standard that most industries abide by. If you adhere to GMA standards, you can be confident that the pallets you purchase can be used by most forklifts, which allows for simple transportation. The dimensions for GMA-style pallets are:

• Wood material
• Stringer-style design
• Dimensions: 40″ x 48″ x 6.5″
• Five bottom and seven top boards
• A minimum thickness of 0.5″
• 4-way forklift entry
• 2,500-pound minimum load capacity
• Top board: 5.5″ x 40″ on both ends and five 3.5″ x 40″ boards along the center
• Bottom boards: 5.5″ x 40″ on both ends and three 3.5″ x 40″ boards between

When using these pallets, your forklift can gain access to them from a side or end, which allows for easy placement in a rack or storage bay.

Types of Pallets

There are two common pallet types that you can buy for your warehouse, which include 2-way and 4-way pallets. The main difference between these pallets involves the entry capability of your forklift. If you buy a 2-way pallet, it can only be lifted from two sides. A 4-way pallet accommodates entry from all four sides.

If you have a limited amount of space in your warehouse, you may benefit from using a 4-way pallet that you can effectively lift from any direction. When cost is the primary factor in your decision-making process, a 2-way pallet may be suitable. Before you buy pallets for your warehouse, consider the pros and cons of each type.

4-Way Pallets

As was mentioned previously, 4-way pallets can be accessed by a forklift from all sides. However, this isn’t the only advantage that comes with using this design in your warehouse. There are multiple types of 4-way pallets you can purchase.

For example, partial 4-way pallets consist of notched stringers along one side that allow them to be lifted on every side by forklifts but only two sides by pallet jacks. If you purchase a 4-way block pallet, you can lift it from any side with a pallet jack or forklift. These pallets offer flexibility in forklift access and enhanced operational efficiency.

2-Way Pallets

Two-way pallets can be used for many storage and material handling applications. You can access these pallets with a forklift or pallet jack from two sides. They are made with solid stringer boards, which is why forklifts can only enter them from two sides. Most of these pallets consist of a middle stringer as well as stringers on both sides. This type of pallet provides durability at a more affordable cost. If you have ample space in your warehouse, consider using 2-way pallets.

Pros and Cons of 4-Way vs. 2-Way Pallets

When you’re weighing your options, consider the pros and cons of each type.

4-Way Pallets

The many advantages of 4-way pallets include the following:

• High durability: If durability is more important to you than cost, block pallets have the highest strength, which means that they provide more weight capacity. These pallets use high-quality wood and a superior design.
• Better operational efficiency: These pallets deliver high durability and strength while also being more flexible.
• High weight capacity: A block pallet comes with a static weight capacity of nearly 3,000 pounds.
• Flexible access: Your forklift or pallet jack can access these pallets from all four sides.

There are also a few drawbacks, which include the following:

• Higher cost: If you want to use block pallets in your warehouse, they cost more than other options because they use a considerable amount of wood.
• Heavier weight: It’s possible for a 4-way block pallet to weigh as much as 80 pounds, which will cause transportation costs to increase.
• Potential environmental concerns: These pallets are usually built with wood from hardwood trees, which take decades to grow. Because of how long it takes for these trees to mature, they’re cut down at a higher rate than they’re replaced.

2-Way Pallets

There are numerous advantages associated with 2-way pallets, which are:

• High durability: The stringers that are used in 2-way pallets are solid, which means that they don’t break as easily as pallets that use notched stringers.
• Cost-effective: You don’t need to use as much materials to build 2-way pallets, which is why they cost less than 4-way platforms.
• Easy to manufacture: These pallets come with simple designs, which makes it easier to build them.

There are also some issues with 2-way pallets, which extend to:

• Limited access points: Your forklifts will only be able to access these pallets from the front or back, which means that it may be more difficult to move them in a warehouse that doesn’t have much floor space.
• Reduced operational efficiency: You’ll notice that 2-way pallets need to be positioned in trucks in a manner that makes them accessible by pallet jack or forklift. In this scenario, you can only arrange loads in specific configurations, which means that trucks will carry fewer pallets in a single load.

Choosing the Right Pallet for Forklift Use

Before you buy pallets for your warehouse or distribution center, there are numerous factors you should consider, which include warehouse space, operational needs, durability, and cost. Whether you’re interested in 4-way or 2-way pallets, weigh the pros and cons of each against your company’s specific needs.

You can also select a less traditional pallet style or material. For example, plastic pallets come with fewer maintenance requirements and higher durability. The main drawback to plastic pallets is that they’re more expensive than their wooden counterparts. While a 2 way pallet provides you with enhanced durability and higher weight capacity, it can hurt the space utilization in your warehouse.

A 4 way pallet delivers ample flexibility and efficiency when it comes to loading and unloading goods. However, a single 4 way block pallet can weigh anywhere from 65-80 pounds, which means that it can effectively increase transportation costs. When searching for the right lifting pallets for your warehouse, you must understand your forklift capabilities and pallet compatibility. Check load size and pallet dimensions to determine if your forklift supports the type of pallet you prefer.

Safety Considerations in Pallet Handling

While pallets make it easier for you to move goods around your facility and into delivery trucks, you must handle them properly with forklifts to ensure the safety of your personnel. Keep in mind that some industries provide specific guidelines and rules for how to use pallets. Check the regulations in your industry before you start using pallets to transport or store goods. The safety standards that you should adopt in your warehouse include the following:

• Don’t store your empty pallets on end
• Your personnel should never stand on pallets
• Don’t lift people with pallets
• Pallets should be stacked at a height that’s less than four feet
• Make sure your work area doesn’t contain any pallet debris
• Remove damaged pallets from the work area immediately after detection
• Use protective gear when handling pallets
• When you need to get items from the back of a specific pallet, use a pick hook

If you intend to use forklifts to transport pallets in your warehouse, your employees must receive the necessary training and certification.

Conclusion

From 2-way pallets to 4-way platforms, there are many sizes, types, and materials you can select for your pallets. Choosing the right pallet type allows you to improve operational efficiency. Assess your company’s specific needs and follow the necessary safety practices for optimal pallet management.