When businesses look for ways to improve export shipping efficiency, they often focus on the product, freight rate, container space and delivery schedule.
The pallet underneath the product may receive much less attention.
However, every pallet becomes part of the shipment.
If the load carrier is heavier than necessary, that additional weight travels through the entire logistics chain — from the factory and warehouse to the truck, port, airport and final destination.
For Malaysian manufacturers exporting regularly, pallet weight can therefore become an important part of the overall transport packaging calculation.
The objective is not simply to find the lightest possible pallet.
It is to use only the amount of packaging weight required to protect, support and handle the product safely.
The Pallet Is Part of Your Total Shipment Weight
Consider a simple shipment.
A manufacturer may calculate the weight of its finished product carefully but overlook the weight added by:
– Pallets
– Boxes
– Protective packaging
– Internal supports
– Strapping
– Stretch film
– Other transport packaging materials
Together, these components become part of the total transported load.
Eltete Malaysia notes that packaging materials contribute directly to overall shipment weight and that reducing unnecessary packaging weight can support transportation efficiency, particularly in weight-sensitive applications such as air freight.
A few kilograms may not appear significant on one shipment.
But the calculation changes when a manufacturer sends hundreds or thousands of pallet loads every year.
Small Weight Differences Can Scale Quickly
Imagine two suitable pallet systems.
1 – Option A
– Product weight: 500 kg
– Pallet and packaging: 25 kg
– Total transported weight: 525 kg
2 – Option B
– Product weight: 500 kg
– Pallet and packaging: 10 kg
– Total transported weight: 510 kg
The difference is only 15 kg per shipment.
But across 1,000 shipments, that becomes:
15 kg × 1,000 shipments = 15,000 kg
That is 15 tonnes of packaging weight being transported.
This example does not mean that freight costs will automatically fall by a fixed percentage. Actual savings depend on freight rates, transportation method, shipment configuration and other commercial factors.
However, it illustrates why packaging weight should be measured rather than ignored.
Eltete recommends evaluating the complete packaging system when calculating export packaging cost instead of considering only the purchase price of the packaging material.
Pallet Weight Matters Most When It Adds No Extra Value
Some packaging weight is necessary.
A load platform must be strong enough to support the product. Protective materials must prevent movement and damage. Reinforcement may be necessary for heavy or concentrated loads.
The problem begins when the packaging becomes heavier than the application actually requires.
For example, a company may automatically use the same pallet specification for every shipment even though:
– Different products have different weights
– Some products require less structural support
– Export destinations differ
– Handling conditions differ
– Some shipments are one-way
– Pallet return is not required
– A smaller custom pallet could fit the product better
In these situations, standardising around a heavier load carrier may introduce unnecessary transport weight.
The better approach is packaging optimisation rather than simply packaging reduction.
Eltete designs its pallet solutions according to the product, handling method and destination, with the aim of optimising strength, space, material use and cost expectations.
Lighter Does Not Mean Weaker
One common assumption is that reducing pallet weight must mean reducing strength.
That is not necessarily the case.
Packaging performance depends on factors such as material construction, load distribution, pallet design, runner position and the way the load is handled.
Eltete Paper Pallets use PallRun® pallet feet, which combine laminated U-profiles with kraftliner surfaces and paper cores.
Eltete states that independent laboratory testing of selected four-way Paper Pallets achieved static compression loads of up to 10,000 kg without failure. This figure relates to tested pallet configurations and should not be treated as the capacity of every Paper Pallet design.
The required pallet should always be selected according to the actual application.
Paper Pallets Can Reduce Non-Product Weight
For companies that still require a conventional pallet-style load platform, Paper Pallets can provide an alternative to traditional wooden pallets.
Eltete’s published information describes its Paper Pallets as:
– Lightweight
– Suitable for heavy loads
– Resistant to side impact and dragging
– Available in customised configurations
– Suitable for international shipping
– ISPM 15-compliant
Eltete’s company information also provides a general comparison in which its Paper Pallets weigh approximately 3 to 6 kg, compared with approximately 15 to 25 kg for wooden pallets used in the comparison. Actual pallet weight depends on dimensions, design and load requirements.
The important point is not that every paper pallet will create the same weight reduction.
It is that exporters have another load-platform option that can be engineered around the actual shipment.
Why This Can Matter for Air Freight
Reducing unnecessary pallet weight becomes particularly relevant when transportation efficiency is sensitive to shipment weight.
Eltete specifically identifies lower weight and transportation savings, including air-freight applications, as benefits of its Paper Pallet solutions.
Imagine exporting relatively lightweight but high-value goods.
If a substantial portion of the transport weight comes from the load carrier itself, using an unnecessarily heavy pallet means paying to transport packaging rather than product.
A lighter suitable pallet can increase the proportion of the shipment weight represented by the actual goods.
This makes pallet optimisation especially worth evaluating for:
– Electronics
– Semiconductor components
– Pharmaceuticals
– Automotive components
– High-value manufactured products
– Frequent international shipments
The actual commercial impact should always be calculated using the company’s real shipment data.
Pallet Weight Also Affects Handling
Freight efficiency is only one part of the calculation.
Pallet weight also affects what happens before and after transportation.
Empty pallets must be:
– Received
– Moved
– Stored
– Positioned
– Prepared for loading
– Moved again after unloading
– Stored, returned or disposed of
A lighter empty load platform can make some of these processes easier.
Eltete identifies easier handling and lower unnecessary pallet weight among the potential benefits of fibre-based pallet solutions.
Safe handling procedures and suitable equipment are still required regardless of pallet material.
The goal is not to replace mechanical handling where it is required, but to avoid moving additional packaging weight that provides no useful function.
Custom Pallet Dimensions Matter Too
Weight and size are connected.
A standard pallet may be larger than the product placed on it.
That can create:
– Unused pallet surface
– Product overhang or poor positioning
– Additional packaging material
– Wasted storage space
– Less efficient container utilisation
Eltete Paper Pallets can be developed in standard or customised sizes according to the product and handling requirements.
A pallet designed around the actual product dimensions can help manufacturers reduce unnecessary material while maintaining the support points required by the load.
This is why pallet optimisation should consider weight, dimensions and load distribution together.
PallRun®: Do You Always Need a Complete Pallet?
Another question worth asking is:
Does the product actually need a separate full pallet?
For some packaging designs, the answer may be no.
Eltete PallRun® is a paper-based pallet runner and one of the basic components used in Eltete Paper Pallets.
Depending on the application, PallRun® can be:
– Attached directly underneath a suitable carton box
– Combined with corrugated board
– Combined with Honeycomb Board
– Used to construct two-way or four-way pallet solutions
– Integrated into customised transport packaging
Eltete describes PallRun® as a lightweight alternative to selected wooden pallet runners.
This opens another approach to reducing packaging weight.
Instead of automatically placing a strong box onto a completely separate pallet, a suitable packaging design may integrate the load-support runners directly into the package.
The box and pallet base effectively become part of one transport packaging system.
Why Integrated Packaging Can Be More Efficient
Traditional packaging can sometimes develop layer by layer.
Product.
Then protective packaging.
Then box.
Then another board.
Then pallet.
Then additional securing material.
Every additional component may have a valid purpose, but the complete system should be reviewed to identify duplicated functions.
For suitable products, integrating PallRun® underneath the outer package can reduce the need for a separate full pallet structure.
This does not mean that every carton should simply have pallet runners attached underneath it.
The outer box, load distribution, runner positions, product weight and forklift handling must all be suitable for the design.
But it demonstrates an important principle:
Efficient packaging should work as one system rather than as a collection of unnecessary layers.
Slip Sheets Take Weight Reduction Further
For some logistics operations, the conventional raised pallet can be removed entirely.
Eltete Slip Sheets are thin sheets manufactured from multiple layers of strong kraftliner board.
Goods are placed directly onto the Slip Sheet instead of a traditional wooden or plastic pallet.
This creates a palletless transport system.
Because the Slip Sheet has a very low profile, it can reduce both the weight and space associated with a conventional pallet.
That can be particularly useful for:
– High-volume exports
– Container shipping
– One-way shipments
– Operations with limited empty-pallet storage
– Supply chains where pallet return is inefficient
Eltete identifies reduced freight, material and storage requirements as potential benefits of its Slip Sheet system.
But Slip Sheets Require the Right Handling System
Slip Sheets should not be selected based on low weight alone.
A conventional forklift normally lifts a pallet through openings underneath the pallet deck.
A Slip Sheet works differently.
The load is normally handled using equipment such as a forklift fitted with a Push-Pull attachment, RollerForks or another compatible system.
Eltete therefore recommends evaluating the complete logistics process before changing from pallets to Slip Sheets.
Important questions include:
– Does the sending warehouse have compatible equipment?
– Can the receiving customer handle Slip Sheets?
– Is the product load stable?
– Is the outer packaging strong enough?
– What Slip Sheet thickness and strength are required?
– Where should the pulling tabs be positioned?
– How will the load be unloaded?
– What are the humidity and transport conditions?
A lighter system only creates an advantage if it works throughout the supply chain.
Q – Paper Pallet, PallRun® or Slip Sheet?
A – There is no single best solution for every shipment.
Choose a Paper Pallet when:
You want to reduce pallet weight while maintaining a familiar pallet-style handling system.
This may be practical for manufacturers that already use conventional forklift operations and do not want to redesign the complete material-handling process.
Consider PallRun® when:
A suitable box, Honeycomb Board or packaging structure can incorporate pallet runners directly.
This may help reduce the need for a separate complete pallet.
Consider Slip Sheets when:
Palletless handling is possible throughout the supply chain and reducing load-carrier weight, thickness and storage space is a priority.
The sending and receiving operations must both be compatible with the handling system.
The correct choice depends on the product, weight, dimensions, handling method, destination and logistics environment.
Do Not Optimise Weight at the Expense of Protection
Reducing pallet weight should never create:
– Unstable loads
– Poor forklift support
– Product movement
– Insufficient stacking strength
– Concentrated pressure
– Packaging failure
– Increased transport damage
A damaged product will normally cost more than the packaging material that was removed.
Eltete’s export packaging guidance therefore emphasises that packaging should provide the required protection with the correct amount of material rather than simply using the minimum possible amount.
The question should not be:
“What is the lightest pallet available?”
It should be:
“What is the lightest suitable packaging system that can safely support this particular shipment?”
Calculate the Weight Across Your Entire Export Operation
Manufacturers can start with a simple calculation.
Current pallet weight × number of shipments per year = annual transported pallet weight
Then compare it with a suitable alternative.
For example:
Current load carrier: 20 kg
Alternative load carrier: 6 kg
Difference: 14 kg
Annual shipments: 2,000
14 kg × 2,000 = 28,000 kg
That means 28 tonnes less load-carrier weight would travel through the transport network over the year.
This does not mean freight costs automatically decrease by the same proportion.
The financial effect depends on:
– Freight pricing
– Transport mode
– Shipment size
– Weight limits
– Container utilisation
– Route
– Shipment frequency
– Handling requirements
But this calculation provides a useful starting point for identifying whether pallet weight deserves more attention.
Look Beyond the Purchase Price of the Pallet
When comparing load carriers, the lowest purchase price is not always the lowest logistics cost.
A more complete evaluation should consider:
Packaging material cost
How much does the complete system cost?
Packaging weight
How much non-product weight is transported?
Transport space
How much room does the pallet or load carrier occupy?
Storage
How much warehouse space is required for empty packaging?
Handling
How is the packaging moved before, during and after shipment?
Return logistics
Does the pallet need to come back?
Destination handling
Can the customer unload the selected packaging system?
Product protection
Does the packaging provide the required strength and stability?
Eltete’s approach is to evaluate transport packaging as a complete system rather than looking at one packaging component in isolation.
Transport More Product, Not Unnecessary Packaging Weight
A pallet may appear to be a small part of the export process.
But when that pallet travels with every shipment, its weight becomes part of every logistics movement.
For manufacturers exporting frequently, the effect can multiply quickly.
The solution is not simply to replace every wooden pallet with a lighter material.
It is to understand what the load actually requires.
A Paper Pallet can provide a lightweight structured load platform.
PallRun® can allow pallet runners to become part of an integrated packaging design.
A Slip Sheet can eliminate the conventional raised pallet altogether where the handling system allows it.
Each approach reduces unnecessary packaging in a different way.
The right solution depends on the product and the complete logistics process.
Because in export shipping, you are not only transporting your product. You are transporting everything underneath and around it too.
For manufacturers looking to reduce unnecessary transport packaging weight while maintaining suitable protection and handling performance, Eltete Malaysia can develop paper-based packaging solutions according to the product, load, handling method and destination.
Learn more at www.eltete.com.my
