Pallet overhang

Overhang is any part of the load extending beyond the pallet footprint. It concentrates damage: overhanging cartons lose up to a third of their stacking strength, get clipped by forklifts and door frames, and destabilize the pallets stacked beside them in a trailer.

Most retail routing guides — Amazon FBA included — specify zero overhang, and chargebacks or refused pallets enforce it. The usual causes are cartons sized without the pallet in mind or one-too-many cases per layer. The fix is arithmetic, not effort: choose the carton orientation and per-layer count that fits inside 48×40 (or your pallet standard) and accept the slightly lower count — it's cheaper than the damage.