If you are trying to make a pallet to put all your mail on, even though you may have a mailing that doesn't meet a minimum quantity to go onto a pallet, you can make a loose pallet (and you'll have to create your own pallet card) by following these instructions:
Browse to C:\Program Files\AccuZIP6 5.0\iPresort\INI Defaults, and open the ADVANCEDSETTINGS.INI File in Notepad or Wordpad.
Add this section to the Advancedsettings.ini file:
[PALLETS]
LOOSE PALLET=1
Close the file, then click Yes to save the changes.
Presort your list again, and your mail should be able to go on one pallet.
Loose Pallet
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Loose Pallet
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