Stackable and nestable are the two most common types of plastic pallet, and the difference between them is simple: a stackable pallet is built to be stacked when it is loaded, and a nestable pallet is built to save space when it is empty.
Get the choice wrong and you either lose warehouse space or pay for strength you never use. Here’s how to decide.
The difference in one line
Nestable pallets have separate legs or feet, usually nine, so an empty pallet slots into the one beneath it.
Stackable pallets have runners (usually three) or a full perimeter base, which spreads the load so pallets can be stacked on top of one another when loaded.
That single structural difference drives everything else.
Load ratings
Every plastic pallet should carry three ratings:
- Static load: the weight it holds resting on a flat floor
- Dynamic load: the weight it holds while being moved by a forklift or pallet truck
- Racking load: the weight it holds when supported only on its edges in beam racking
Stackable pallets generally carry higher dynamic loads than nestable pallets. Neither type should go into beam racking unless it is specifically rated for it; that’s the job of a third type, the rackable pallet.
Nestable pallets
The advantage is space when empty. A stack of empty nestable pallets takes up a fraction of the room of the same number of flat-based pallets, which matters on return journeys and in yards where empties pile up.
The trade-offs: lower dynamic loads, no racking capability, less stable on conveyors and some automated systems, and loaded nestable pallets generally shouldn’t be stacked on one another.
Best for:
- Export and one-way shipments where the pallet may not come back
- Lightweight goods such as boxed ambient food, bottled drinks or packaging
- Sites where storage space for empties is tight
- Replacing wooden pallets on export routes to avoid ISPM 15 treatment and marking
Stackable pallets
The advantage is space when loaded. Loaded pallets can be block-stacked several high without racking, and runner or perimeter bases run smoothly on roller conveyors.
The trade-offs: they don’t nest, so empties take up considerably more space, and they cost more than an equivalent nestable pallet.
Best for:
- Block-stacked storage in chilled and ambient food warehouses
- Conveyor and automated handling systems
- Closed-loop distribution between fixed sites
- Hygienic production areas, using closed-deck versions
| Feature | Nestable | Stackable |
|---|---|---|
| Empty storage | Most compact | Takes full footprint |
| Stack when loaded | Generally, no | Yes |
| Dynamic load | Lower | Higher |
| Beam racking | No | Only if rated |
| Conveyors | Limited | Good |
| Cost | Lower | Higher |
| Typical use | Export, one-way, light loads | Block storage, closed loops |
How it plays out in practice
Food and drink. A producer shipping ambient goods to export customers uses nestable pallets, since nothing needs to come back and there’s no ISPM 15 treatment to arrange. The same business block-stacks chilled stock in its cold store on hygienic stackable pallets. Most food operations end up running both. See more on food sector handling.
Manufacturing. Heavier finished goods and closed-loop deliveries to regular customers generally point to stackable pallets, with nestable pallets reserved for one-way export shipments.
3PL and distribution. Where stock is stored in racking rather than block-stacked, neither type is right and you need rackable pallets instead. See Exporta’s 3PL and distribution support.
Sizes
Both types come in the two main UK and European footprints: 1200×1000mm (UK standard) and 1200×800mm (Euro). Match the pallet to your vehicles, racking beams and customers’ requirements before choosing a type.
How to decide
Three questions settle it:
- Does the pallet come back? If it’s one-way, nestable almost always wins on cost and return space.
- Will loaded pallets be stacked or go on conveyors? If yes, stackable.
- Where do the empties go? If empty storage or return transport is the constraint, nestable.
If the answer is beam racking, you need a rackable pallet rather than either of these.
Exporta stocks stackable and nestable plastic pallets with next-day UK delivery. Browse plastic pallets or ask the team which type suits your loads.
