Shipping trays of beverage cans on pallets is a common logistics method used by breweries, beverage startups, co-packers, and distributors. Palletizing trays allows companies to move large quantities of product efficiently through warehouses, freight networks, and retail distribution channels while minimizing product damage. When done correctly, palletized tray shipments improve handling efficiency, protect cans from dents, and reduce overall shipping costs.
Why Beverage Cans Are Shipped in Trays on Pallets
Corrugated trays are widely used in the beverage industry because they provide structural support and stability for aluminum cans during storage and transportation. These trays hold groups of cans—often 12, 16, or 24 units—while allowing easy stacking and shrink-wrapping.
Palletizing trays provides several benefits:
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Efficient material handling using forklifts and pallet jacks
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Improved warehouse storage density
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Reduced product damage during transit
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Faster loading and unloading of trucks
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Simplified inventory management
For large shipments, pallets also allow beverages to move through automated distribution centers and pallet racking systems without manual handling.
Standard Pallet Configuration for Beverage Cans
In North America, the most common pallet size used for beverage shipments is 48 × 40 inches. Depending on the size of trays and cans, pallet configurations may vary, but a typical pallet of beverage cases can hold roughly 100 cases when stacked in stable layers.
Typical pallet structure:
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Pallet base: 48” × 40” wood or plastic pallet
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Cases per layer: ~10 cases depending on tray size
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Layers per pallet: 8–10 layers
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Total cases per pallet: 80–100 cases
The exact count depends on factors such as tray design, can size (12 oz, 16 oz, slim cans), and allowable stacking weight.
Common tray configurations include:
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16 pack can trays
Proper Pallet Stacking Techniques
Correct stacking is critical when shipping beverage trays. Poor stacking can lead to pallet collapse, crushed cans, or product loss during transportation.
Best practices include:
1. Even Weight Distribution
Heavier cases should be placed on the bottom layers, while lighter cases go toward the top to maintain stability.
2. Interlocking Layer Patterns
Alternating the orientation of trays between layers creates a stronger pallet structure and prevents “column stacking” collapse.
3. Avoid Pallet Overhang
Cases should never extend past the pallet edge because overhang can significantly reduce stacking strength and expose products to damage.
4. Maintain a Square Load
Pallet loads should form a consistent cube shape with a flat top rather than a pyramid shape to maximize stability during transport.
5. Be aware of freight classifications. These change constantly. For instance, new freight rules for beer and some other types of beverages are coming soon.
Stabilizing Palletized Beverage Shipments
Once trays are stacked, the entire pallet must be secured to prevent shifting during truck transport.
Common stabilization methods include:
Shrink Wrap or Stretch Film
Industrial stretch film tightly secures trays to the pallet, preventing movement during transit and protecting against environmental exposure.
Corner Boards / Edge Protectors
Rigid corner boards reinforce pallet edges and improve compression strength during stacking and shipping.
Layer Sheets or Slip Sheets
Corrugated sheets placed between layers increase stability and help distribute weight across trays.
Strapping or Banding
Some shipments use plastic straps to add additional structural support to the pallet load.
Handling and Transportation Considerations
Palletized beverage trays may travel through multiple stages before reaching their destination, including:
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Brewery, beverage production facility, or co-packers
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Regional distribution centers
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Freight carriers or LTL shipping terminals
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Retail warehouses or store distribution hubs
Because pallets may be loaded and unloaded several times, maintaining strong pallet integrity is essential. Sudden stops, forklift impacts, and warehouse transfers can easily shift unsecured trays and dent cans.
Optimizing Palletized Beverage Shipments
To reduce shipping costs and damage rates, beverage brands should focus on:
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Using high-strength corrugated can trays designed for stacking. Whale Pod Shipper stocks many different sized beverage can trays. These include 12 and 24 packs, for 12oz, 16oz, and sleek style cans. Using high quality beverage trays like these is crucial in pallet optimization.
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Keeping pallet loads consistent by SKU
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Avoiding excessive pallet height
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Applying tight shrink wrap from pallet base to top
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Conducting compression testing for tray strength
Well-designed tray packaging can significantly reduce losses caused by dented cans and collapsed pallets.
Conclusion
Shipping trays of beverage cans on pallets is one of the most efficient methods for transporting large beverage volumes through modern supply chains. By combining durable corrugated trays, proper stacking patterns, and secure pallet wrapping, beverage brands can ensure their products arrive intact and ready for distribution.
For growing beverage companies and breweries, investing in optimized palletization practices not only protects product quality but also improves logistics efficiency across the entire supply chain.