5.4 Palletizing & Container Loading
Stability, load security,Palletizing and transportcontainer safety.
loading Palletizingtransform is about turning many boxes into one solid, steerable load that survives forklifts, hard brakes, and long rides. The aim is stability: keep the centerdozens of gravity (CG = where the weight balances) low and the footprint fully on the pallet. Simple tools—corner boards, stretch wrap, and straps—lock everythingcartons into a single block,stable whileunit “blockthat can withstand forklifts, braking trucks, and brace”ocean (wedges/barsvoyages. thatThe stopgoal sliding)is keepssimple stacksbut quietunforgiving: insidekeep aweight trailerbalanced, orcartons container. Moisture and climate matter too, so choose materials that won’t sag or soak through on the route. Do this wellsupported, and the onlyload thinglocked movingso init transitmoves isas theone. truck.Pallet choice, stack pattern, and restraint methods decide whether shipments arrive intact or collapse under pressure. Moisture, temperature swings, and route conditions add further demands, making packaging a true engineering discipline rather than a final afterthought.
5.4.1 The goal (in one line)
Build a single, rigid unit (pallet + cartons) that survives forklifts, brakes, bumps, humidity, and time—then lock it safely inside a truck or container.
5.4.2 Pick the right pallet (size, strength, compliance)
Rating: know the pallet’s dynamic/load rating and don’t exceed it. No overhang—cartons must sit fully on deck boards.
5.4.3 Stack pattern & height (strength vs stability)
- Column stack (aligned corners): max strength (best for ECT); use when cartons are strong and uniform.
- Interlocked (brick): more stable, but reduces column strength—use only if needed.
- Slip sheets/anti-slip between layers minimize shear.
- Height & CG: heavier layers low; keep center of gravity near pallet center; target H ≤ 1.5× base unless spec’d otherwise.
- Clearances: leave ~50 mm (2”) from skid edge to wrap; nothing should hang out.
5.4.4 Lock the load (wrap, strap, protect)
Stretch-wrap recipe (starter)
- Rope band the film and trap under deck with 2–3 passes to tie load to pallet.
- Bottom: 3–5 wraps with 50% overlap.
- Mid: 2–3 wraps; add cross “X” if tall.
- Top: 2–3 wraps; capture top cap if used.
- 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 for most loads; steel only for very heavy/rigid items. Always use edge protectors under straps.
- Void fill: honeycomb blocks/airbags inside the pallet footprint (not sticking out).
5.4.5 Carton & pallet labels (traceable and readable)
- Carton: SKU/Variant, quantity, unit SN range if serialized, orientation/fragile graphics.
- Pallet: pallet ID, SKU(s), count, gross weight, destination, stack limit, and handling icons 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)
5.4.11 Common traps → smallest reliable fix
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)