Roll Storage Fundamentals — Strength, Entry Types and Compliance
Storing and handling rolls is not the same as storing boxes. A roll is a concentrated load on a curved surface, often heavy, often sensitive. This page explains how to choose a pallet that holds it safely — and clears up the three misunderstandings that cause most wrong decisions: entry type versus racking, real load resistance, and food compliance.
Who this page is for
The market for roll pallets splits in two. On one side, light one-way plastic pallets sold mainly on price — a crowded market with endless supply. On the other, durable reusable pallets in special sizes and shapes, chosen for reuse, safety, cleanliness and compliance in regulated industries such as food and pharmaceutical packaging.
ROLL works on the second side. If the lowest possible unit price is the only thing that matters, many suppliers can help. If the roll must be held safely, cycle after cycle, in a clean and compliant way, the choice is narrower — and the technical detail below is where it is decided.
The three internal-use situations
Before talking about strength, you have to know how the pallet will be stored and moved. There are three cases, and the right pallet is different for each.
1. Floor and AGV handling
The pallet lives on the floor and is moved with pallet trucks and, increasingly, AGVs (automated guided vehicles). For this you normally need 4-way entry, so the unit can be picked up from any side by a pallet truck.
The catch: a 4-way pallet without bottom cross-members cannot go on racking. It is built for the floor, not for being supported only at its edges. Choosing 4-way for floor flexibility can quietly rule out racking later.
2. Shelving (full-surface support)
This is the middle case. The pallet rests on a continuous shelf or panel, supported across its whole base. Almost any pallet type works here, because the support is even. The thing to check is not the pallet — it is the rated capacity of the shelf itself, which must carry the roll plus the pallet.
3. Racking (edge support)
This is the case most people underestimate. On racking the pallet is supported only at its edges, on the rack beams, with nothing underneath the centre. A roll sitting on it is a concentrated load pressing down on an unsupported span.
Roll pallets on racks need steel reinforcement
Without metal reinforcement bars, a plastic roll pallet on racking will deflect. The concentrated weight of the roll, combined with temperature and time, weakens and stresses the plastic until the deck sags between the beams.
This is why ROLL rack-compatible roll pallets carry steel reinforcement. A standard floor pallet placed on a rack is one of the most common and most dangerous mistakes in roll storage.
The strength misunderstanding: which number really matters
Pallet performance is tested under the international standard ISO 8611, which measures three different load conditions. They are not interchangeable.
| Load type | What it means | When it applies |
|---|---|---|
| Static load | Weight a pallet holds while resting on the floor, not moving | Pallet stored on the ground |
| Dynamic load | Weight a pallet holds while being moved by a truck or AGV | Every time the load is handled |
| Racking load | Weight a pallet holds when supported only at its edges on beams | Pallet stored on racking |
Under ISO 8611 the rated value is the maximum working load for a specific support condition, with a safety factor of at least 2.0 applied. There are two traps for roll handling:
- Static is the easy number. A headline figure such as “5000 kg” usually means static load, on the floor. The dynamic and racking values are always lower.
- Standard ratings assume a distributed load. The figures are measured with the weight spread evenly across the whole deck. A roll does the opposite: it puts a concentrated load on a narrow contact line.
Do not compare a standard pallet rating to a roll pallet
A standard pallet rated “5000 kg” (static, distributed, on the floor) is not comparable to what a roll pallet must survive: a heavy, concentrated load, often in motion, sometimes on rack beams. Reading a standard distributed-load rating as if it described roll service is how pallets fail under coils.
Pallet sizes and codes
Principal pallet dimensions are defined by ISO 6780, which lists six international footprints: 1200×800, 1200×1000, 1000×1200, 1100×1100, 1067×1067 and 1140×1140 mm. In Europe the most common are the EUR / EPAL 800×1200 mm and the 1000×1200 mm format. Pallet terminology is standardised by ISO 445.
These footprints were designed for boxes and unit loads, not for cylinders. Rolls come in their own diameters, lengths and weights, which is why roll handling so often needs formats outside the standard grid. ROLL builds pallets around the roll — cradle profiles, reinforced decks and special sizes for specific diameters and weights — rather than forcing a roll onto a flat box pallet.
Food contact vs food-packaging suitability
This is the third common misunderstanding, and it matters in food and pharmaceutical plants. A pallet that carries rolls of food packaging film is not in direct contact with food. It supports the packaging, which in turn contacts the food.
EU food-contact law reflects this. Direct food-contact plastics must comply with the framework Regulation (EC) 1935/2004, the plastics Regulation (EU) 10/2011 with its migration limits, and good manufacturing practice under Regulation (EC) 2023/2006; recycled food-contact plastics additionally require an authorised process under Regulation (EU) 2022/1616.
How ROLL states it
All ROLL products are suitable for the food packaging industry. They are designed to be used safely around food packaging operations.
Direct food-contact compliance is a stricter, separate claim. ROLL can declare it only for products made from virgin material, where the composition can be controlled against Regulation (EU) 10/2011. ROLL declares this status product by product — it does not describe itself as “food-contact certified” across the range.
Full food-contact position
How ROLL assesses products against EU food-contact rules.
Choosing the right pallet: a quick map
| Storage method | Entry / support | What to check |
|---|---|---|
| Floor & AGV | 4-way entry for pallet trucks | Dynamic load rating; 4-way may exclude racking |
| Shelving | Full-surface support | Rated capacity of the shelf itself |
| Racking | Edge support on beams | Steel reinforcement; racking load with concentrated roll |
Frequently asked questions
Can any plastic pallet be placed on racking?
No. On racking the pallet is supported only at its edges, not across its whole base. A roll pallet carrying a coil applies a concentrated load, so without steel reinforcement bars the deck deflects and sags over time. A pallet rated for floor use is not automatically safe on racking.
What does a 5000 kg pallet load rating actually mean?
A headline figure like 5000 kg usually refers to the static load, on the floor, with the weight spread evenly across the whole deck. That is the easiest condition. It does not describe how the pallet behaves in motion (dynamic load) or under the concentrated load of a single roll, which are the conditions that matter for roll handling.
Why do roll pallets need steel reinforcement bars on racks?
A roll is a concentrated load resting on a narrow contact line, and on racking the pallet is held only at its edges. Combined with temperature and time, this stresses the plastic and makes the deck flex. Steel reinforcement bars keep the deck rigid so the pallet does not sag between the rack beams.
Do I need a 4-way pallet for pallet trucks and AGVs?
For floor handling with pallet trucks and AGVs a 4-way entry is normally required so the unit can be picked from any side. But a 4-way pallet without bottom cross-members cannot be placed on racking. Matching entry type to the storage method is essential.
Are ROLL pallets food-contact certified?
ROLL pallets are not designed for direct contact with food. They are designed to be suitable for packaging that in turn contacts food. All ROLL products are suitable for the food packaging industry; direct food-contact compliance with EU Regulation 10/2011 can be declared only for products made from virgin material.
Which standards apply to pallet strength and dimensions?
Pallet performance is tested under ISO 8611 (static, dynamic and racking load, with a safety factor of at least 2.0). Principal dimensions are defined by ISO 6780, and pallet terminology by ISO 445. The US equivalent test method is ASTM D1185.
Can ROLL make non-standard pallet sizes and shapes for rolls?
Yes. Beyond the standard ISO 6780 footprints, ROLL specialises in pallets built around the roll itself — cradle profiles, reinforced decks and special sizes for specific roll diameters and weights. This is the core of the ROLL range.
Note on standards and figures
This page is provided for guidance. Load ratings, entry types and compliance status depend on the specific product, roll format and conditions of use, and must be confirmed for each case. References to ISO and EU instruments are to the standards and regulations in force; ROLL declares compliance as a downstream user on the basis of its own assessment and of supplier documentation. Contact ROLL for figures and declarations specific to your application.