How can I get more product on a pallet?

How to get more on a pallet

Do you need to reduce your labour, materials and logistics costs?  Reviewing how you palletise your finished product could be the key to unlocking savings in all these areas.

The size and specification of your corrugated cases can have a considerable impact on the number of products shipped per pallet of finished goods, or how many flat boxes you can get on a pallet of goods coming in.  The number of inbound pallets shouldn't be overlooked.  If we can reduce the number of pallets of boxes in your warehouse, you can increase the amount of *space dedicated to raw materials or finished goods.

The case size will be determined primarily by the number of products it holds inside.  This may be dictated by your end consumer but if there is a degree of flexibility, our design team can assist you in determining the optimum number of products per box for optimum pallet fill.  You can see a great example of how a 3 x 2 configuration compares with a 2 x 4 alternative layout in our previous article on how to reduce your packaging costs.

Existing corrugated cases have often been in use for many years and after such long periods, a review of their layout can often identify where changes can be made. A relatively small change or reduction in the internal dimensions, can often increase the number of cases per pallet layer and make even better use of the pallet deck area.

Case specifications also provide a great opportunity to increase pallet fill. There is now a much wider selection of alternative flute profiles, and several “niche” flute profiles have become “mainstream” and are widely used. After well over a decade the “new” intermediate flute profile is a great example; I Flute (or X-Flute, etc.) can offer a 20% reduction in thickness (or to use the technical jargon, calliper!) compared to B Flute, reducing the outside dimensions of a case and therefore increase the number of cases per layer!

Another consideration is accessing the benefits of “performance packaging” (in industry "language") or what board grade the case is made up of.  This effects the corresponding compression strength of a box; a stronger grade of the liner (the outside, inside paper or fluting grade used to make up the box) could achieve the benefit of going a layer higher on a pallet. Using clever software (available from your friendly Dairi-Pak team!) can often enable you to safely achieve that extra layer of cases on a pallet. This extra fill per pallet often more than offsets the costs of the increase in board grade.

The swift and easy process of exploring and achieving optimal pallet fill is simplified by using state-of-the-art palletisation software. The inputs entail looking at your primary product and the output provides both case size, board grades and various specification options. It can also calculate the maximum load per pallet (helping with calculating complete lorry load weights too).

The benefits to your business from maximising your pallet fill and optimising your board grade include:

  • Using fewer pallets
  • Using less stretch wrap
  • Less space needed to store the same number of flat boxes 
  • Increased space on the factory floor/packing area
  • Ability to hold more stock in existing warehouse space
  • Reduced transportation cost
  • Reduced labour costs
  • Reduced environmental impact

If you would like to explore how you can benefit from this great cost-saving opportunity, please just give us a call or email us to find out how to get more of your product on your pallets!

T: 019393 260342 E:

*Check out our just in time service for another way to reduce your on site stock holding of packaging supplies!

How can we help you? Get in touch about your packaging requirements

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