Small cartons need a pallet surface that supports their bases without leaving critical edges spanning large openings. Check the smallest carton in the bottom layer against the actual gaps between deckboards, rather than choosing a pallet by its outside dimensions alone. A carton can fit inside the pallet footprint yet still sag or become damaged if its base is poorly supported.
Depending on the product and packaging, suitable options may include a closer deckboard arrangement or an approved load-distribution sheet. A loose sheet does not automatically increase the pallet’s load rating or solve an unsuitable design. Ask your packaging specialist and pallet supplier to review the bottom-layer layout, carton strength, total load and handling conditions together. AR Pallets’ custom pallet service is the relevant starting point when a standard deck layout does not suit your cartons.