7 Need-to-Know Tips for Packing a Strong Pallet

Those of you who are involved in manufacturing or distribution are probably storing and/or sending out boxes of product stacked on pallets or slip sheets. These unitized loads offer an efficient way to move product from point A to point B, and unitized loads provide an easy way to store goods in a warehouse. But, if you are experiencing damage or frequent returns, it may be time to take another look at your boxes and how you are stacking them. When it comes to stacking and improving pallet density and stability, remember these 7 rules…

1. Heavy goods go first
2. Up the edge of the pallet, but not hanging over
3. Place boxes like you would bricks
4. Avoid a pyramid-shaped pallet
5. Secure it with strapping
6. Pick the best stretch wrap for the project
7. Plan ahead… Rethink your strategy

If you or your employees are doing the stacking, there are some things you should take into consideration (if you aren’t already). For example, did you know that the four vertical corners of a box provide the majority of its stacking strength? And that it’s important to align the corners of the box above with the corners of the box below?

Additionally, there are things that should be avoided such as allowing your boxes to hang off the edge of your pallets. This is called overhang, and, due to having unsupported box corners, it can lead to catastrophic failures of your unitized loads. Overhang and other misuses of pallets account for nearly half of observed damage, according to The Food Marketing Institute. 35% of this damage is attributed to pallet overhang and 50% is attributed to poor pallet stability. (Fundamentals of Packaging Technology, c.2013)

Other factors also contribute to the performance of unitized loads. For example, does your warehouse have an uncontrolled climate? If so, then in the summer you often have high humidity that can drastically affect the strength of your boxes. This is a common situation that will affect the stacking strength of boxes, but with proper planning, we can ensure that your corrugated boxes are made with correct board grade for the job. The duration of pallet stacking and whether or not unit loads are stacked atop one another also have a direct impact on the likelihood of damage.

At FlexPAC, we have a palletization program that helps determine the right corrugated board grade for a given situation.  It also calculates the best ways to arrange and stack boxes. If your boxes are crushing while stacked in your facility, please contact us and allow FlexPAC to help you find the right solution.