5.4 Palletizing and Container Loading

The final logistical step — palletizing and container loading — is mandatory for protecting the product during the highest mechanical stress phase (transit). This process must be treated as an extension of the packaging design, requiring intentional bracing and stacking to mitigate damage from vibration, shock, and excessive compression forces. These procedures are mandatory for minimizing shipping damage and maximizing container utilization.

5.4.1 Palletization Protocol

The pallet is the primary handling unit in the logistics chain. Its structure and assembly directly affect the survival of the stacked cartons.

A) Pallet Selection and Footprint

• Choice: Select the pallet (e.g., 48 x 40 inch GMA for North America; 1200 x 800 EU) based on the destination flow and racking size.
• Rating: The pallet's dynamic/load rating must not be exceeded.
• Overhang Prohibition: Prohibited is any carton overhang beyond the pallet edges. Overhang exposes carton walls to direct impact and compromises the vertical load capacity, leading to crush failure. All cartons must sit fully on deck boards.
• Export: Wood pallets for export must be heat-treated and stamped (ISPM-15 HT); plastic or presswood is acceptable for closed-loop flows.

B) Carton Stacking and Strength

• Column Stacking Mandate: Cartons must be stacked columnar (box-on-box) rather than interlocked (brick pattern). Column stacking maximizes the strength of the carton's corners (which carry the vertical load) and is the best pattern for utilizing the Edge Crush Test (ECT) rating.
• Stability: Use slip sheets or anti-slip mats between layers to minimize shear movement.
• Height and CG: Keep the center of gravity low; heavier layers must be placed at the bottom. Target height (H) should be ≤ 1.5x the base unless otherwise specified.

C) Locking the Load

• Corner Boards and Top Cap: Corner boards (full height) are mandatory to stop edge-crush and distribute the strapping force. A Top Cap must be used to protect from overhead dust and spread strap pressure.
• Stretch-Wrap Recipe: The load must be secured to the deck. Rope band the film and trap it under the deck with 2 – 3 passes to physically tie the goods to the pallet. The bottom requires 3 – 5 passes with 50% overlap. Tension must be consistent.
• Strapping: Use PET/PP strapping for most loads. Always use edge protectors under strapping to prevent the strap from cutting into the carton.

5.4.2 Container Loading and Bracing

Loading containers requires intentional bracing to prevent catastrophic cargo movement during high G-forces (acceleration/deceleration).

A) Load Planning and Distribution

• Load Map: A formal Load Plan (stowage diagram) must be used to map rows and layers before loading begins.
• Weight Placement: Weight must be placed forward and low, centered left/right to avoid heavy bias at the doors. Spread concentrated loads with dunnage boards.
• Forklift Reality: Fork entries must be clear (no wrap covering them). Fork spread must utilize the outer third of the pallet.

B) Void Control and Bracing

• Void Control Mandate: Any gap (void) between pallets or cartons must be eliminated to prevent movement, abrasion, and rattling.
• Bracing: Voids must be filled using dunnage airbags or wooden shoring. Airbags must be protected with corrugated sheets and inflated to the specified pressure.
• Bulkhead: Build a false bulkhead (honeycomb/corrugated) at the doors and strap it to lashing rings to stop fore-aft slide during braking.
• Moisture Control: Desiccant must be sized to the route/climate and hung high along the container length. Record the door seal number on paperwork.

5.4.3 Documentation and Traceability

Logistical documentation must be accurate and readable for customs, delivery, and traceability.

A) Labeling and Orientation

• Carton Label: Must include SKU/Variant, Quantity, UPC/EAN, and orientation/fragile graphics.
• Pallet Label: Pallet ID, SKU(s), count, gross weight, and destination must be legible on two adjacent faces.
• Orientation: UP arrows and fragile warnings must be clearly marked and oriented correctly on all sides of the carton.

B) Verification and Audit

• Load Test: Perform a Push Test (firm hip-push) to confirm the load does not shift laterally. Perform a Tilt Test (10˚ – 15˚) to verify stability.
• Wrap Test: The film must be tight and springy, not slack.
• Traceability: Master carton contents (the range of product SNs) must be logged and linked to the electronic ASN (Advanced Shipping Notice).

Final Checklist

Mandate	Criteria	Verification Action
Stacking Pattern	Cartons stacked columnar; anti-slip used; heavy items low.	Prohibited is using the interlocking (brick) pattern.
Overhang Control	Zero overhang past the pallet edges; corners protected by boards.	Audit confirms vertical capacity is not compromised (> 32% reduction risk).
Load Securing	Stretch wrap rope banded to the pallet deck; straps use edge guards.	Push Test and Tilt Test confirm load stability.
Void Control	All gaps in the container/truck are eliminated with dunnage or bracing.	Final audit confirms the cargo is tightly secured against movement.
Pallet Health	Pallets verified for capacity; ISPM-15 HT stamp present for export wood.	Inspect for protruding nails or wet/weak deck boards.
Labeling	Pallet ID, weight, and destination on two adjacent faces.	Final check confirms orientation arrows are correct and legible.