5.4 Palletizing and Container Loading

A) Pallet Selection and Footprint

• Choice: (pallet + cartons) that survives forklifts, brakes, bumps, humidity, and time—then lock it safely inside a truck or container.

  
  

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  5.4.2 PickSelect the right pallet (size,e.g., strength,48 compliance)x 40 inch GMA

  for North America; Choice1200 x 800 EU	) based on the destination flow and racking size. WhenRating: 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 usedirect impact and compromises the vertical load capacity, leading to crush failure. All cartons must sit fully on deck boards. Export:	Notes
  48×40” (GMA)	NorthWood America	4-way entry; common racking size
  1200×800 (EU)	EU flows	Check racking beam spacing
  1200×1000 (ISO)	APAC/EMEA mixed	Goodpallets for cubeexport of 40’ containers
  Wood (ISPM-15 HT)	Export	Mustmust be heat-treated &and stamped (ISPM-15 HT); noplastic bark/nailsor proud
  Plastic/presswood	Closed loop,is dampacceptable routes	Clean,for light;closed-loop checkflows. deck B) stiffness/rackCarton rating

  Rating: know the pallet’s dynamic/load ratingStacking and don’t exceed it. No overhang—cartons must sit fully on deck boards.

  
  

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  5.4.3 Stack pattern & height (strength vs stability)

  Strength
  • Column stackStacking (aligned corners):Mandate: Cartons must be stacked max strengthcolumnar (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); use when cartons are strong and uniform.rating.
  • Interlocked (brick):Stability: Use moreslip stable,sheets butor reduces column strength—use only if needed.
  • Slip sheets/anti-slip mats between layers to minimize shear.shear movement.
  • Height &and CG: heavierKeep layersthe low; keep center of gravity nearlow; palletheavier centerlayers 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:; target HCorner ≤ 1.5× baseboards unless(full spec’dheight) otherwise.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.
  • Clearances:Stretch-Wrap Recipe: leaveThe ~50load mmmust (2”)be from skid edgesecured to wrap; nothing should hang out.
    

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  5.4.4 Lock the loaddeck. (wrap, strap, protect)

  Stretch-wrap recipe (starter)

  1. Rope band the film and trap it under the deck with 2–2 – 3 passes to physically tie loadthe goods to the pallet. The bottom requires 3 – 5 passes with 50% overlap. Tension must be consistent.
  3. Bottom: 3–5 wraps with 50% overlap.
  3. Mid: 2–3 wraps; add cross “X”Strapping: ifUse tall.
  4. Top: 2–3 wraps; capture top cap if used.
  5. Film tension consistent; no film tails.

  Add-ons (choose by risk)

  • Corner boards (full height) to stop edge-crush and give belts something to bite.
  • Top cap (corrugated or hardboard) spreads strap pressure; protects from overhead dust.
  • Strapping: PET/PP strapping for most loads; steel only for very heavy/rigid items.loads. Always use edge protectors under straps.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.
  • VoidWeight fillPlacement:: honeycombWeight blocks/airbagsmust be placed insideforward and low, centered left/right to avoid heavy bias at the palletdoors. footprintSpread concentrated loads with dunnage boards.
  • Forklift Reality: Fork entries must be clear (notno stickingwrap out)covering them). Fork spread must utilize the outer third of the pallet.

  
  

  B)

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  Void

  5.4.5 Carton & pallet labels (traceableControl and readable)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,Quantity, UPC/EAN, and unit SN range if serialized, orientation/fragile graphics.graphics.
  • Pallet Label:: palletPallet ID,ID, SKU(s), count, gross weight,weight, and destination must be legible on destinationtwo adjacent faces.
  • Orientation:, stackUP limitarrows, and handlingfragile iconswarnings 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. Mixed pallets: diagonal band or big MIXED placard; pack list in a clear sleeve. 5.4.6 Forklift reality (design for handling) Fork entry: 4-way preferred; fork pockets clear (no wrap covering them). Fork spread ≈ outer third of pallet; no tip-lifting one edge. Do not pierce cartons (keep forks level, travel low). No double-stack unless cartons and pallet are rated—if allowed, use slip sheets and corner boards between stacks. 5.4.7 Container loading (build a safe, quiet cube) Plan the load Create a load map: rows, layers, and aisle (if needed) before the door opens. Weight forward & low, centered left/right; avoid heavy bias at the doors. Keep even floor loading; spread concentrated loads with dunnage boards. Block & brace No overhang at container walls; leave 20–50 mm breathing gap. Use chocks, cribbing, and load bars to stop fore–aft slide. Dunnage airbags fill side gaps—inflate to spec; protect with corrugated. Build a false bulkhead (honeycomb/corrugated) at the doors; strap to lashing rings. Moisture control Desiccant sized to route/climate; hang high and spread along the length. Use container liners/VCI for corrosion-sensitive goods. Close doors with seals; record seal number on paperwork. 5.4.8 Environmental & legal notes (fit for route) Temp swings: avoid films that embrittle in cold; keep desiccant away from direct water; avoid air-cell cushions at altitude unless spec’d. Regulatory: hazmat/UN boxes follow their own rules; lithium batteries need the correct marks and packing (if present in your product). Weight limits: confirm axle/legal weights with logistics; heavy pallets can tip you over—better to split. 5.4.9 Quick tests that prevent headaches Push test: a firm hip-push shouldn’t shift the top layer. Tilt test: pallet tilted ~10–15° briefly—nothing slides. Wrap test: pluck the film; it should feel tight and springy, not slack. Short ride: forklift over a speed bump—no sway, no strap chatter. 5.4.10 Acceptance cues (fast table) Area Accept Reject Footprint No overhang; even clearance to edges BoxesFinal hangingcheck off;confirms wraporientation coveringarrows forkare entries Stack Columncorrect (orand controlled interlock); heavy low Random brick; tall light box on bottom Wrap/strap Rope banded to pallet; tight film; edge-guarded straps Film tails; straps cutting cartons; no pallet tie Protection Corner boards/top cap as needed Crushed corners; strap marks Labels Pallet ID, weight, destination on two faces Handwritten mystery; one-side only Container Blocked/braced; gaps filled; desiccant hung Free-to-slide stacks; no moisture controllegible. 5.4.11 Common traps → smallest reliable fix Trap Symptom First move Overhang to “use all space” Crushed corners, failed ECT Zero overhang; re-cut foam or change pallet Brick stack by habit Column strength lost Use column stack; add anti-slip for stability Wrap not tied to pallet Load walks off deck Rope band under deck; 3–5 bottom wraps Straps without edge guards Carton damage lines Add corner boards/edge protectors Heavy up high Tip, sway, collapsed lower boxes Re-layer: heavy low; limit height; top cap No brace in container Shift, door avalanche Build bulkhead; use airbags/load bars Wet/weak pallets Breakage, nails through cartons Inspect & reject bad pallets; use ISPM-15 HT 5.4.12 Pocket checklists Before build Pallet size/rating fits route; ISPM-15 for export Carton stack plan picked (column preferred); heavy low Corner boards/top cap/anti-slip staged; film & straps ready Build No overhang; ≥ 50 mm from edges to wrap Rope-band film under deck; bottom 3–5 wraps; top 2–3 wraps Straps with edge guards; labels on two faces with pallet ID & weight Container Weight centered; rows blocked/braced; airbags used where gapped Desiccant/liner as required; seal applied & number recorded Photo of load map and first/last rows (if customer/audit requires) By stacking smart, tying loads firmly to the pallet, and blocking or bracing inside containers, shipments stay secure through handling and transit. This discipline minimizes damage, prevents safety hazards, and ensures products arrive exactly as packed, ready for customers without rework or loss. Back to top