Stock manager looking at palleted goods on truck trailer

 

For businesses involved in haulage, logistics or goods distribution, maximising trailer space is essential. Making the most of every load not only improves efficiency but also reduces costs and increases profit margins. Whether you're moving full pallet loads or mixed cargo, understanding how to utilise space effectively can make a real difference to your operation.

In this article, we’ll explore how to optimise your trailer capacity, taking into account things like pallet sizes, trailer dimensions and the different types of trailer design you might be dealing with. If you’re transporting freight regularly, this guide can help you get more value out of every journey.

 

Why Trailer Space Optimisation Matters

Empty or underused space in a trailer is essentially lost revenue. The goal for any haulier or fleet operator is to move as much product as possible, safely and legally, within a single journey. If you’re able to increase the number of pallets per load, reduce empty space or better plan your stacking, you stand to benefit in several ways:

  • - Lower fuel cost per unit
  • - Fewer journeys required
  • - Reduced wear and tear on vehicles
  • - Improved customer service through more efficient delivery

Before looking at optimisation techniques, it’s important to understand the variables involved - namely pallet dimensions, trailer types and legal weight or height limits.

 

Common Pallet Sizes and Configurations

Pallets come in a range of sizes depending on region, industry and cargo type. The most common standards used across Europe and beyond include:

 

1. Euro Pallet (EUR / EPAL)

  • - Size: 1200mm x 800mm
  • - Load capacity: Typically up to 1,500kg
  • - Usage: Widely used across Europe, especially in retail and logistics

 

2. UK Standard Pallet

  • - Size: 1200mm x 1000mm
  • - Load capacity: Around 1,000kg to 1,200kg
  • - Usage: Common in the UK for both domestic and international freight

 

3. North American Pallet (GMA)

  • - Size: 1219mm x 1016mm
  • - Load capacity: Similar to Euro and UK pallets
  • - Usage: Standard in the United States and Canada

 

4. Half Pallets and Quarter Pallets

  • - Smaller formats used for lighter or more compact goods. While easier to handle, they can be inefficient if not carefully arranged.

 

The size of the pallet determines how many can be fitted into a trailer, both in terms of floor space and vertical stacking. Inconsistent pallet sizes or irregular stacking can lead to wasted space and unstable loads.

 

Understanding Trailer Types and Dimensions

The type and size of trailer you use will also influence how much freight can be carried. Here’s a quick overview of the most common trailer options:

 

1. Standard Curtainsider (Articulated Trailer)

  • - Internal dimensions: Approximately 13.6m (L) x 2.45m (W) x 2.5m (H)
  • - Typical pallet capacity: Up to 26 UK pallets or 33 Euro pallets in a single layer

 

2. Box Trailer

  • - Similar capacity to curtainsiders but with rigid sides, offering greater protection for high-value or sensitive goods.

 

3. Double Deck Trailer

  • - Capacity: Can carry 40 to 50 pallets (depending on load height and trailer design)
  • - Benefit: Excellent for maximising volume, especially with lighter goods

 

4. Urban or Rigid Trailer

  • - Size: Often shorter, between 8–10 metres
  • - Usage: Common in city centres or local deliveries where space is limited

 

5. Flatbed and Skeletal Trailers

  • - Typically used for containers or non-palletised goods, but can carry palletised loads when appropriately secured

 

6. Refrigerated (Reefer) Trailers

  • - Similar layout to box trailers but slightly reduced internal space due to insulation and cooling equipment

 

Each trailer type has its own advantages depending on the cargo. The key to optimisation is choosing the right trailer for the job and planning pallet loads accordingly.

 

Techniques to Maximise Pallet Space

Once you’ve understood the basic constraints of pallet size and trailer type, the next step is to apply strategies that make the best use of available space.

 

1. Use the Correct Pallet Size for the Trailer

A Euro pallet is narrower than a UK standard pallet, which means more Euro pallets can be arranged side-by-side within a standard trailer. For example:

  • - 33 Euro pallets fit in a standard 13.6m trailer (11 rows of 3)
  • - 26 UK pallets is the usual maximum (13 rows of 2)

Choosing the more space-efficient pallet type for your trailer can significantly increase load capacity.

 

2. Consider Stacking, If Safe and Permitted

If the load is stable, stackable and within legal height limits, double stacking can double your trailer's pallet capacity. However, this depends on:

  • - The strength and condition of the pallets
  • - The type of goods being transported
  • - Whether the trailer height allows for safe stacking
  • - Weight distribution and road safety regulations

 

3. Invest in Load Bars and Decking Systems

Double deck trailers or adjustable decking systems allow goods to be carried on two levels without stacking directly on top of each other. This is ideal for fragile or non-stackable goods, allowing you to fully utilise the trailer height without compromising safety.

 

4. Reduce Empty Gaps with Efficient Packing

Empty gaps between pallets or around the trailer edges waste space. Using dunnage, void fillers or narrower pallets in strategic positions can help make the most of awkward gaps.

Some operators also use warehouse management systems (WMS) or load planning software to visualise how cargo will fit in advance.

 

5. Balance Weight Distribution

Maximising space should never come at the expense of safe weight distribution. Overloading one section of the trailer, especially the rear, can make handling dangerous and may lead to fines or roadside delays.

Use axle load calculators or consult your vehicle’s specifications to ensure weight is spread evenly and legally.

 

Trailer Height and Legal Limits

Before stacking or loading taller pallets, always check the legal height restrictions for your route. In the UK, the maximum vehicle height is usually 4.95m, but many roadways have bridges lower than that.

For European routes, the legal height limit may differ from country to country. Be especially cautious when transporting tall or double-stacked pallets across borders.

 

Final Thoughts

Maximising trailer space is both a science and an art. It requires a combination of the right equipment, proper planning and an understanding of how different pallet and trailer sizes interact. Whether you’re looking to improve your operational efficiency or reduce your cost per delivery, making better use of trailer space is one of the simplest and most effective strategies available.

At Law Trucks, we offer a wide range of quality used trailers, including curtainsiders, box trailers and double deck options. If you're looking for a trailer that suits your loading requirements, our team is happy to advise based on your specific needs.