Amazon FBA
Pallet Configuration for Amazon FBA
Pallet configuration for Amazon FBA LTL shipments follows a specific set of rules — and getting any one of them wrong means your freight gets refused, re-palletized at your expense, or delayed at the fulfillment center. This guide covers every requirement from pallet selection through stretch wrap, in the order you'll actually build a shipment.
When You Need to Palletize for FBA
Amazon requires LTL freight — and therefore palletized shipments — when any of the following apply:
| Condition | Threshold | Notes |
|---|---|---|
| Shipment weight | > 150 lbs | Above this threshold, LTL is eligible and typically cheaper |
| Box count | > 200 boxes | Amazon may require palletization above this count |
| Individual box weight | > 50 lbs | Heavy boxes require pallet or team-lift label |
| Seller preference | Any shipment size | You can choose LTL for any shipment if you prefer pallets |
If your shipment qualifies for LTL, you'll select it during shipment creation in Seller Central. Everything below applies once you've chosen that path.
Amazon FBA Pallet Requirements at a Glance
These are Amazon's non-negotiable baseline specs for every LTL pallet arriving at a fulfillment center:
| Requirement | Amazon Spec | Why It Matters |
|---|---|---|
| Pallet dimensions | 40" × 48" GMA | Fits FC conveyor and racking systems |
| Pallet type | Wood, 4-way entry | Required for forklift access on all sides |
| Pallet condition | New or like-new | No broken boards, no protruding nails |
| Max total height | 72" (floor to top) | Includes pallet deck (~5.5"); some FCs up to 98" |
| Max pallet weight | 1,500 lbs | Including pallet weight (~40–50 lbs) |
| Case overhang | Not permitted | All boxes must stay within 40×48" footprint |
| Max single box weight | 50 lbs | Heavier boxes need team lift / mechanical lift label |
| Stackable | Yes — required | Amazon double-stacks pallets in most FCs |
| Stretch wrap | Required | Full coverage; must not cover labels |
Stackability note
Amazon routinely double-stacks pallets at fulfillment centers. This means the top layer of your pallet needs to support another full pallet on top of it. Use a brick stacking pattern (alternating layers), avoid top-heavy loads, and ensure your top layer is flush — no leaning cases.
Step-by-Step: Building an FBA Pallet Shipment
Create Your Shipping Plan in Seller Central
In Seller Central, go to Inventory → Send to Amazon (or Manage FBA Shipments, depending on your interface). Select the items you're shipping and the quantity per box. When prompted for shipment type, choose Less Than Truckload (LTL).
What Amazon assigns at this stage:
- Your destination fulfillment center (you don't choose this)
- Shipment ID — needed for your pallet labels
- Box content requirements — whether Amazon needs a box-level manifest
Calculate Your Pallet Configuration
Before you touch a box, calculate how many boxes fit per layer and how many layers high you can go. This determines how many pallets you'll need — which you'll enter into Seller Central before printing labels.
The formula
Boxes per floor layer:
(40 ÷ box L) × (48 ÷ box W)
Round down. Try both orientations.
Layers high:
66" ÷ box H
66" = 72" total minus ~6" pallet deck. Round down.
Total boxes per pallet = floor layer × layers high
A typical FBA shipping carton (16×14×12") works out to:
| Step | Math | Result |
|---|---|---|
| Boxes along 40" side | 40 ÷ 16 = 2.5 → 2 | 2 |
| Boxes along 48" side | 48 ÷ 14 = 3.4 → 3 | 3 |
| Boxes per floor layer | 2 × 3 | 6 |
| Layers high (66" ÷ 12") | 66 ÷ 12 = 5.5 → 5 | 5 |
| Total boxes per pallet | 6 × 5 | 30 |
Always check the rotated orientation too. Swapping length and width on the floor layer can add an extra box per layer — which compounds across 5 layers and multiple pallets.
Run this calculation in the Pallet Calculator →Label Your Boxes First
Every box going into an Amazon FC needs the correct FNSKU barcode on the outside. Apply box labels before you start stacking — not after. Trying to label boxes mid-pallet or through stretch wrap creates errors and scan failures at receiving.
Single-ASIN boxes
One FNSKU label per box, applied to a flat side with no seams. Label must be scannable and face outward when the box is stacked.
Mixed-ASIN boxes
Each box must contain one ASIN only. The box label identifies the ASIN. Do not mix ASINs within a single box — the FC cannot split them at intake.
Stack Your Pallet
Stack boxes using a brick (interlocking) pattern — alternating the orientation of each layer so vertical seams don't align. This is the difference between a pallet that survives a 500-mile LTL haul and one that arrives as a collapsed mess.
✓ Brick / interlocked stacking
Each layer rotates 90°. Corners and edges of boxes rest on the center of the boxes below them. Significantly more stable under vibration and shifting.
✗ Columnar / block stacking
Boxes stack directly aligned corner to corner. Maximizes count but creates vertical shear planes — the pallet can collapse sideways in transit. Not recommended for Amazon shipments where double-stacking is the norm.
Stacking rules to follow:
- → Heaviest boxes on the bottom layers, lighter on top
- → Keep all boxes within the 40×48" pallet footprint — no overhang
- → Same box size per pallet where possible — mixed sizes create uneven loads
- → Every layer must be complete and level — a partial top layer is unstable
- → No leaning or tilting boxes — if your top layer won't sit flat, rebuild it
Apply Pallet Labels
Print your pallet labels from Seller Central after entering your pallet count and dimensions. Amazon generates a unique label per pallet tied to your shipment ID. These are different from your box labels — one set per pallet, not per box.
Label placement — exactly
- → 4×6 inch label on each of the four sides of the pallet
- → Placed in the top center of each side, near the top of the load
- → Applied before stretch wrapping
- → Labels must be fully visible through the wrap — do not cover with stretch film or tape
- → One unique label per pallet — do not reuse labels across pallets
If you have multiple pallets in a single shipment, each gets its own label from Seller Central. Print the set, keep them in order, and apply them before wrapping.
Stretch Wrap the Pallet
Stretch wrap secures the load to the pallet and prevents shifting in transit. Amazon requires it — a pallet arriving unwrapped or with loose wrap is subject to refusal. Here's how to do it correctly:
Bottom anchor — start here
Begin at the pallet deck, wrapping the film around the bottom boards of the pallet itself — not just around the boxes. This anchors the load to the pallet. Apply at least 4 revolutions at the base.
Spiral up
Work your way up the pallet in a tight spiral, overlapping each pass by about 50%. Apply enough tension to compress the load slightly — you want the film tight, not decorative. Continue to the top of the load.
Top cap and diagonal
Apply at least 4 revolutions at the top. Then add diagonal passes from top corners to base corners on all four sides — these resist racking forces that spiral wrapping alone doesn't address.
✗ Do not cover your labels
Apply wrap so all four pallet labels remain fully visible and scannable. If a label gets covered, cut the wrap back and expose it — Amazon scanners at receiving will reject a pallet that can't be identified on all sides.
Enter Pallet Details and Schedule Pickup
Back in Seller Central, enter your final pallet count, the dimensions and weight per pallet, and confirm your freight readiness date. This is also where you choose between Amazon's Partnered Carrier Program and your own carrier.
Amazon Partnered Carrier
Amazon negotiates LTL rates on your behalf. Typically the lowest-cost option for most US lanes. You book through Seller Central; Amazon bills your account. Best for sellers without established carrier relationships.
✓ Lower rates ✓ Amazon-managed pickup
Non-Partnered Carrier
Use your own carrier and rate. Useful if you have a preferred carrier, a broker relationship, or are shipping from a region where partnered rates are less competitive.
You manage booking, BOL, and pickup coordination
Whichever you choose, confirm the PRO number or carrier tracking ID and enter it in Seller Central before your freight arrives at the FC. Shipments that arrive without tracking confirmation get held at receiving.
Ti-Hi and Amazon FBA
Amazon doesn't use Ti-Hi notation the way Walmart does — there's no item setup field in Seller Central that asks for Ti and Hi separately. But the underlying concept is exactly what drives your pallet configuration:
Ti
Tier
Boxes per floor layer
Hi
High
Layers per pallet
= Total boxes per pallet — the number you enter into Seller Central
Where Ti-Hi matters directly for Amazon is in the pallet count calculation. When you create your shipment plan and tell Amazon how many boxes you're sending, it calculates how many pallets to expect based on the boxes-per-pallet figure you enter. If that figure doesn't match your physical pallets, the FC receives a different quantity than your shipment plan shows — triggering a receiving discrepancy.
Calculate your Ti-Hi before finalizing your shipment plan, not after. It takes 60 seconds and prevents a discrepancy that can hold your inventory in receiving limbo for days.
Calculate Ti-Hi →Common Reasons Amazon Refuses or Flags FBA Pallets
Most FBA pallet rejections are preventable. Here's what FC receiving flags most often:
| Issue | Result | Prevention |
|---|---|---|
| Pallet label covered by stretch wrap | Receiving hold | Apply labels before wrapping; check all 4 sides after |
| Pallet exceeds 72" total height | Refused or re-palletized at your cost | Measure after building — tape measure, not estimate |
| Case overhang | Refused | Verify boxes sit within 40×48" before wrapping |
| Collapsed or leaning pallet | Refused; damage claim possible | Use brick stacking; don't skip the base anchor wrap |
| Box count doesn't match shipment plan | Receiving discrepancy; inventory held | Confirm Ti-Hi before entering pallet count in Seller Central |
| Damaged pallet boards | Refused | Inspect pallets before building — replace any with cracked boards |
| Missing PRO number in Seller Central | Shipment held at receiving | Confirm carrier tracking number before delivery appointment |
| Mixed ASINs in a single box | Processing delay; may be unfulfillable | One ASIN per box — no exceptions |
Frequently Asked Questions
What size pallet does Amazon FBA require?
Amazon FBA requires 40×48-inch GMA pallets for LTL shipments. Pallets must be wood, 4-way entry, and in new or like-new condition with no broken boards or protruding nails.
What is the maximum pallet height for Amazon FBA?
Amazon FBA pallets must not exceed 72 inches total height measured from the floor, including the pallet itself. That leaves approximately 66 inches of usable load height above the pallet deck. Some fulfillment centers accept up to 98 inches for specific product types — check your destination FC in Seller Central.
How much can an Amazon FBA pallet weigh?
FBA pallets must not exceed 1,500 lbs including the pallet itself (~40–50 lbs). Individual boxes must not exceed 50 lbs unless marked with a team lift or mechanical lift label.
How many boxes fit on an Amazon FBA pallet?
It depends on your box dimensions. A typical 16×14×12" FBA carton fits roughly 30 boxes per pallet (6 per layer × 5 layers) on a 40×48" pallet loaded to 60". Use the Pallet Calculator with your actual box dimensions for an exact number.
Can you mix ASINs on an Amazon FBA pallet?
Yes — Amazon allows mixed-ASIN pallets for LTL as long as each individual box contains only one ASIN and is correctly labeled with the FNSKU barcode. Single-ASIN pallets process faster at the FC and are preferred when your shipment volume allows it.
Where do pallet labels go on an Amazon FBA shipment?
Amazon requires a 4×6-inch pallet label in the top center of each of the four sides. Labels must be applied before stretch wrapping and must remain fully visible through the wrap. Covered labels cause receiving holds.
What is Amazon Partnered Carrier for LTL?
Amazon's Partnered Carrier Program lets sellers use Amazon-negotiated LTL rates — typically lower than market rates for most US lanes. You book through Seller Central and Amazon bills your account. Non-partnered means arranging your own carrier, useful if you have a preferred carrier relationship or better rates on certain lanes.
Tools to Build Your FBA Pallet Config
Pallet Calculator
Enter your box dimensions and get boxes per layer, total stack, and weight — the numbers you need before creating your Seller Central shipment plan.
Ti-Hi Calculator
Calculate your tier and high configuration. Useful if you also sell through Walmart or other retail channels with formal Ti-Hi requirements.
Load Planner
Shipping a full truckload to an Amazon FC? Plan your pallet count, trailer fit, and weight distribution across a 53-foot dry van.