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A pallet pad is a protective sheet (usually corrugated, chipboard, kraft paperboard, or honeycomb) placed on top of, under, or between layers of product on a pallet to protect cartons, spread weight, and stabilize the load.
In plain English: it’s the “buffer layer” that keeps pallets from getting dented, crushed, scuffed, or unstable during shipping.
Now let’s make it crystal clear — what it is, what it does, where it goes, and when you should use it.
What A Pallet Pad Does (The Real Jobs)
A pallet pad is used to do 5 big things:
1) Protect Cartons From Damage
It prevents:
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scuffs and rub marks
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punctures from staples/splinters
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abrasion from friction
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dirt and grime transfer
This is huge if pallets sit on docks, travel LTL, or get moved around a lot.
2) Spread Load Weight (Stops Crushing)
Pallet loads don’t always distribute weight evenly.
Pads help spread weight across a larger surface so you don’t get:
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crushed bottom cartons
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collapsed corners
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“sinking” in one area of the stack
3) Add Stability (Reduces Shifting and Leaning)
Pallet pads can reduce movement between layers, especially when used as tier sheets.
Less movement = fewer shifts = fewer claims.
4) Improve Strapping and Wrap Performance
When used on top, pads act like a top cap (more on that in a second), which helps:
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straps avoid digging into cartons
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wrap avoid crushing top edges
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maintain load shape
5) Keep Product Cleaner
Pads act as a barrier against dust, moisture splash, and warehouse grime.
They’re not waterproof, but they’re a clean line of defense.
Where Pallet Pads Are Used (Top, Bottom, or Between Layers)
This is where the terminology gets sloppy. “Pallet pad” is a broad term, and people use it for a few placements:
Bottom Pad (Under the Load)
Placed between the pallet deck boards and the bottom layer of cartons.
Used to:
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prevent punctures from rough pallet boards
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block dust/grime
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spread load weight
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reduce carton damage on the bottom layer
Top Pad (On Top of the Load)
Placed on top like a top cap.
Used to:
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distribute strap pressure
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prevent top carton crushing
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protect from dust and contact
Tier Pad / Tier Sheet (Between Layers)
Placed between layers of product.
Used to:
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stabilize stacked layers
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spread weight
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reduce shifting
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prevent scuffing between layers
So when someone says “pallet pad,” you always want to ask internally: Top, bottom, or between?
Because the function changes based on placement.
Pallet Pad vs Top Cap vs Tier Sheet (Quick Clarity)
Here’s the simplest way to keep it straight:
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Pallet pad = general term for protective sheets used on pallets
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Top cap = specifically a top pad used for strapping/wrap protection
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Tier sheet = pad placed between layers to stabilize and distribute weight
All three can be made from similar materials — the name changes based on where it goes and what it’s doing.
What Pallet Pads Are Made Of
Corrugated Pads
Most common, cost-effective, good protection for many loads.
Best for:
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general carton protection
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top/bottom pads
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standard shipping
Chipboard Pads
Denser and thinner than corrugated.
Best for:
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spreading weight
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resisting strap dents when used on top
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clean presentation loads
Honeycomb Pads
High compression strength, lightweight, very rigid.
Best for:
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heavy loads
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tall stacks
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long-haul/LTL
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export
Kraft Paperboard Sheets
Economical barrier layer.
Best for:
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clean separation
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dust barrier
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light-duty protection
When You SHOULD Use Pallet Pads (No Guessing)
Use pallet pads when:
1) Bottom cartons get damaged
If the bottom layer is crushing, scuffing, or puncturing — bottom pads fix a lot of that.
2) You’re stacking layers and shifting happens
Tier pads reduce movement and help stacks stay square.
3) You strap pallets and cartons dent
Top pads/top caps distribute strap pressure so straps can be tight without crushing product.
4) Your pallets are rough or inconsistent quality
Pads create a smooth surface even when pallets aren’t perfect.
5) You’re shipping LTL or long-haul
Rough handling + vibration makes friction damage and shifting more likely. Pads help stabilize.
6) Presentation matters
Retail and branded cartons arrive cleaner with pads.
How To Choose The Right Pallet Pad
Pick based on:
1) The problem
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punctures/scuffs? corrugated/kraft works
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crushing? chipboard or honeycomb
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heavy loads? honeycomb
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general protection? corrugated
2) Pallet footprint
Match pad size to your pallet (common 48×40), or cut to your load footprint.
3) Load weight and stacking
Heavier and taller stacks need stronger material.
4) Shipping method
Local = lighter duty often works.
LTL/long-haul/export = go stronger.
Best Practice “Damage-Proof” Setup (Simple and Effective)
For carton pallets that get strapped and wrapped:
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Bottom pad (protect base + spread weight)
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Tier pads (if stacking layers that shift)
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Top pad (as top cap for strapping)
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Cornerboard/edge protectors + straps + wrap
That system is how you stop the most common pallet failures: crushed corners, punctures, and loose shifting loads.
Bottom Line
A pallet pad is a protective sheet used on top of, under, or between layers on a pallet to prevent damage, spread weight, and stabilize loads. It’s one of the simplest, cheapest ways to reduce scuffs, punctures, crushed cartons, and shifting during transit—especially when paired with proper strapping and edge protection.