Pallet Covers / Top Sheets: What They Are and Why They Matter

Pallet covers and top sheets are simple but powerful packaging accessories: flat sheets of material—often plastic, paper, or coated fabrics—laid over the top of a pallet load to provide protection and improve load stability. Unlike full pallet covers or stretch hoods that wrap all sides of a load, top sheets typically cover only the top surface and sometimes the upper sides, making them quick to use and cost-effective for many everyday applications.

This entry explains what pallet covers/top sheets are, the common materials and types, where they are used, and the benefits they bring to supply chains of all sizes.

Common materials and types

• Polyethylene (PE): Lightweight, moisture-resistant plastic sheet material available in many thicknesses. PE top sheets are popular where simple water or dust resistance is needed.
• Biaxially Oriented Polypropylene (BOPP): Offers higher tensile strength than basic PE and can be used where additional tear resistance is useful.
• Paper and kraft top sheets: Recyclable and often used when scratch protection or a surface barrier is needed without plastic use. Coated paper adds some moisture resistance while remaining recyclable.
• Coated fabrics/laminates: For heavier duty needs, laminated fabrics or film composites provide superior puncture and abrasion resistance while also offering moisture barriers.
• Perforated or breathable sheets: Used for products that need air circulation (e.g., produce) to avoid condensation or spoilage.

Typical uses and industries

• General warehousing: Protects pallet tops from dust, dirt and incidental drips during storage.
• Retail distribution: Keeps packaged goods clean and presentable for retail shelves after transit.
• Food and beverage: Paper or breathable top sheets are used to control moisture while protecting bulk cases, bags or crates.
• Manufacturing and industrial: Shields sensitive surfaces from scratching or contamination during handling.
• Export and long-haul shipping: Used under stretch film or shrink wrap to prevent film abrasion and add a moisture barrier.

Benefits of using pallet covers / top sheets

• Cost-effective protection: Top sheets are inexpensive compared with full covers or corrugated solutions, offering a fast way to protect many pallets cheaply.
• Reduced waste and handling time: Because a top sheet is quick to apply, it speeds palletizing workflows and reduces handling compared to heavier protective options.
• Improved load appearance: Keeps the top layer of goods clean and tidy, which is important for retail deliveries and customer perception.
• Compatibility with stretch wrap: Top sheets are often used under stretch film to prevent film tearing on sharp edges and to add an extra moisture shield.
• Versatility: Available in many sizes and materials to suit fragile products, moisture-sensitive goods, or eco-friendly preferences.

How they fit into warehouse processes

Pallet covers/top sheets are normally applied after product stacking and before stretch-wrapping or strapping. A worker places the sheet over the top of the pallet load—sometimes folding down the sides slightly—or a top-sheet dispenser integrated into a palletizing line can automate the placement. Because of their simplicity they integrate easily into semi-automated and manual workflows and are often kept as a standard item in packing stations.

Real-world examples

• A beverage distributor uses PE top sheets over stacked cases of bottled drinks. The top sheets prevent condensation from dripping onto the top layer and protect labels during transit.
• An electronics manufacturer places anti-static coated top sheets over pallets of circuit boards to prevent dust and minor abrasions while the load waits for shipment.
• A produce packer opts for perforated kraft top sheets to allow airflow, preventing condensation and prolonging shelf life during short deliveries.

Limitations and considerations

Top sheets are not a universal solution. They do not secure a load in the same way as stretch wrap or rigid containment, so they must be used alongside appropriate restraint methods when loads are unstable or exposed to significant movement. They also offer limited protection against heavy impacts or complete immersion in water. Material choice matters: a plain paper sheet may not protect well in wet environments, while plastic sheets may not be suitable where recycling or biodegradability is a high priority.

Choosing the right top sheet

Select a material and thickness based on exposure risks (moisture, abrasion, puncture), product sensitivity (scratch, static), and sustainability goals. Consider standard sizes that match your pallet dimensions to reduce waste, and explore dispensers or automated feeders if large volumes are used to streamline application.

Summary

Pallet covers / top sheets are a practical, inexpensive protective option for palletized goods, offering dust, moisture and abrasion protection with minimal handling time. When paired with appropriate load-securement methods, they improve product appearance, reduce damage risk and fit easily into most warehouse and distribution workflows. For many beginners in logistics, top sheets are an accessible first step toward better pallet protection and packaging efficiency.