How to Prepare Palletized Cargo for Cold Storage to Avoid Repacking Fees

Why Pallet Preparation Matters in Cold Storage

When cargo arrives at a cold storage warehouse damaged, unstable, or non-compliant, staff may need to repack or restack your goods — and those services aren’t free.

Repacking fees can range from $30 to $100+ per pallet, depending on labor time and materials. Proper preparation not only saves you money but also ensures your goods are protected in the cold chain from port to warehouse.

Use the Correct Pallet Type and Size

Most U.S. cold storage facilities require:

Standard GMA Pallets – 48” x 40”

Food-grade, clean pallets – no dirt, oil, or chemical residue

Good condition – no broken boards or protruding nails

📌 Pro Tip: Avoid non-standard pallets unless your warehouse has confirmed they can accept them.

Keep Pallets Within Height and Weight Limits

Typical cold storage guidelines:

Max height: 60–72 inches (including pallet)

Max weight: 2,000–2,200 lbs per pallet

Overheight or overweight pallets may require split loads — adding to handling costs.

Wrap and Secure Properly

Your shrink-wrap should:

Fully cover the product and extend to the pallet base

Be tight enough to prevent shifting during transit

Use corner boards to protect edges if needed

Avoid loose or hanging wrap that can catch on racking

📌 Pro Tip: In cold storage, condensation and low temps can weaken poor-quality stretch wrap. Use industrial-grade film designed for cold environments.

Label Clearly and Correctly

Each pallet should have:

Product name

Lot/batch number

Quantity and weight

Temperature requirements

Any special handling instructions

Place labels on at least two visible sides for quick scanning.

Prevent Overhang

Product should not extend beyond the pallet edge — overhanging cases are more likely to be damaged during forklift handling and may require repacking.

Use Slip Sheets When Required

Some cold storage facilities prefer or require slip sheets for certain products. If your product will be handled with push-pull attachments, confirm in advance to avoid transfer delays.

Communicate with Your Warehouse Before Shipping

Send your cold storage provider:

Pallet count and configuration

Dimensions and weight

Expected arrival date

Special handling requirements

📌 Pro Tip: This allows the warehouse to plan space and staffing — and flag any compliance issues before your truck arrives.

How Royal Foods Helps You Avoid Repacking Fees

At Royal Foods Distribution, we work closely with shippers to ensure cargo arrives ready for storage:

Pallet prep guidelines sent before your shipment

On-site receiving team trained in cold chain best practices

Quick feedback if your load arrives with issues — so you can correct before storage fees pile up

Final Takeaway

A little extra care in pallet prep can save hundreds in unnecessary repacking charges and keep your perishable products safe from damage.

📦 Contact Royal Foods Distribution Today

Ensure your goods are pallet-perfect before hitting cold storage.

📞 Phone: (408) 560-1628 or (408) 368-0408 📧 Email: [email protected] 📍 Address: 2026 Martin Ave, Santa Clara, CA 95050, USA