What Pallet Sizes Should Your Operation Stock? A Buyer's Guide for Midwest Warehouses
Most Midwest warehouses run on 48x40 GMA pallets, but that is not the whole picture. The right pallet size for your operation depends on your industry, your racking system, and what your customers or suppliers expect to receive. Ordering the wrong size means pallets that do not fit your equipment, cause rejected loads, or waste storage space. Here is a practical breakdown of the most common pallet sizes used across Midwest manufacturing and warehousing, and when each one makes sense.
The 48x40 GMA Pallet: The Default Choice
The 48x40 pallet is the most widely used pallet size in the United States. It fits standard 53-foot trailers two across, matches the depth of standard warehouse racking, and works with most forklift configurations without any adjustment. If your operation does not have a specific requirement driving you toward a different size, 48x40 is almost certainly the right answer. It is the size most suppliers stock in the deepest volumes, which also means faster availability and more competitive pricing.
Other Common Pallet Sizes and Where They Are Used
48x48 pallets are standard in the drum, chemical, and paint industries. The square footprint works well for round or cylindrical loads and aligns with how those industries ship.
42x42 pallets are used in the telecommunications and paint manufacturing sectors. If you supply or receive from companies in those industries, you may need to match their pallet size.
48x45 pallets are common in automotive supply chains. If you are in or adjacent to auto manufacturing in the Midwest, especially in Illinois, Indiana, or Michigan, your customers may specify this size.
36x36 pallets appear in beverage and some retail applications. Less common in general warehousing, but worth knowing if you serve those markets.
What Happens When You Order the Wrong Size
The cost of the wrong size
A pallet that is too wide for your racking creates a safety risk. One that is too narrow for automated conveyors causes jams and damaged product. And if you ship to a customer who requires a specific pallet size, receiving the wrong one can mean a rejected load at the dock.
Stocking Multiple Sizes
Some operations need more than one pallet size. A common approach is to run 48x40 GMA pallets for the majority of operations and keep a smaller stock of a specialty size for specific customers or product lines. Talk to your supplier about whether they can supply both sizes, and what minimum order quantities look like for each. Before placing your order, confirm: what your racking, equipment, and stretch wrappers require; whether any customers or shipping partners specify a size; whether you need multiple sizes; and whether new or recycled condition is required (customer-facing shipments typically need new pallets).
Atlas Pallets and Packaging supplies new and recycled pallets to manufacturers, warehouses, and 3PLs across the Midwest. We stock GMA 48x40 in volume and can source specialty sizes. Request a quote or call us to talk through what your operation needs.