A pallet can look secure inside the warehouse and still become unstable during transportation.
Once the shipment starts moving, it may experience forklift handling, truck vibration, braking, turning, container movement and repeated loading or unloading.
A small weakness in the pallet configuration can then become a larger problem.
Cartons may shift.
The load may lean.
Straps may loosen.
Corners may become crushed.
In more serious cases, part of the load may collapse.
For manufacturers and exporters, pallet load stability should therefore be checked before every shipment leaves the facility.
Eltete Malaysia recommends looking at the pallet, product arrangement, Edgeboard, strapping, wrapping and supporting packaging materials as one complete transport system.
Here are seven areas manufacturers should check.
1. Check the Load Alignment
Start by looking at the shape of the complete pallet.
– Are the cartons aligned?
– Are all layers positioned correctly?
– Does the load form a consistent shape?
– Poor alignment can create weak areas before the pallet even starts moving.
– For example, if several cartons are positioned further out than the layer below, those boxes may have less support. The load may also become harder to secure with wrapping or strapping.
– Eltete recommends using a consistent stacking pattern, aligning boxes correctly and avoiding unnecessary gaps between cartons when building a palletised load.
1.1 – Watch for Pallet Overhang
– Products should generally fit within the intended pallet dimensions. Pallet overhang happens when part of the carton extends beyond the edge of the pallet.
This exposed section may be more vulnerable to:
– Forklift impact
– Contact with nearby pallets
– Crushed carton edges
– Unsupported loading
– Package deformation
– Eltete recommends matching the pallet dimensions to the product rather than forcing the product onto an unsuitable pallet size. Before shipping, stand back and look at the complete pallet from every side.
– A stable load should not already appear uneven or leaning before movement begins.
2. Check the Weight Distribution
– A pallet may be perfectly aligned and still be unstable if the weight is distributed poorly. The position of heavier products matters.
– If most of the weight is concentrated on one side, the load may behave differently during forklift handling, braking or turning. Where the product allows it, heavier items should normally be positioned in a way that creates a stable base.
– Eltete’s load-stability guidance recommends reviewing product dimensions, weight, arrangement and handling conditions when designing the complete pallet configuration.
Manufacturers should ask:
Q – Is most of the weight concentrated in one area?
Q – Are heavy cartons positioned above weak cartons?
Q – Are there narrow contact points transferring high loads into the pallet?
Q – Is the centre of gravity too high?
Q – Is the pallet designed for the actual weight distribution?
– A load does not become stable simply because the total pallet weight is within an acceptable range.
– How that weight is positioned also matters.
3. Check the Strapping
– Strapping is commonly used to hold goods together and secure them during transportation. But more strapping does not automatically mean a more stable pallet.
The strap needs the correct:
– Position
– Material
– Number
– Tension
– If the tension is too low, the load may move. If the tension is too high, the strap may crush cartons or damage exposed product corners.
– Eltete notes that excessive strapping pressure can cause crushed corners, package deformation and other damage.
– Before shipping, check whether the straps remain firmly positioned around the load.
Look for signs such as:
– Loose straps
– Straps cutting into cartons
– Crushed corners underneath straps
– Deformed packages
– Straps sitting in the wrong position
– Uneven strap tension
– A strap should help secure the load without damaging the packaging it is supposed to protect.
4. Check the Stretch Wrapping
– Stretch film can help keep cartons together as one palletised unit. However, wrapping should not be treated as the only solution for an unstable pallet.
– If the products are badly stacked or the pallet configuration is unsuitable, adding more film may only hide the underlying problem.
– Eltete identifies stretch film as one component that can be combined with Edgeboard, pallets and strapping within a complete load-stabilisation system.
Manufacturers should review:
Q – Does the film hold the load together?
Q – Is enough of the lower load connected to the pallet?
Q – Is the wrapping pressure suitable?
Q – Are the cartons becoming compressed?
Q – Are there areas that remain loose?
Q – Has the film been damaged?
– Also check what happens when the pallet moves. Wrapping that appears tight while stationary may perform differently during actual handling.
5. Check the Edgeboard
– The vertical corners are important structural areas of many palletised loads. When cartons are stacked together, these corners help maintain the overall shape of the unit.
– Eltete Edgeboard is a laminated paperboard profile that can be placed vertically along the outside corners of palletised loads.
According to Eltete, Edgeboard can support:
– Palletisation
– Stabilisation
– Unitisation
– Corner protection
– Stacking strength
– Strapping protection
– It can be combined with stretch film, plastic strapping or steel strapping as part of a complete packaging system.
Q – Why Edgeboard Helps Load Stability
A – Imagine several cartons stacked together without external corner support. Each carton can move slightly on its own. When vertical Edgeboards are placed around the corners and the complete load is wrapped or strapped, the arrangement can help maintain a more defined outer shape.
– The Edgeboard also protects vulnerable corners. When a strap passes over an exposed carton corner, pressure may be concentrated on one small area. When Edgeboard is positioned underneath the strap, it creates a larger contact surface and helps distribute that pressure.
– Check the Edgeboard Position
Before shipping, make sure the Edgeboard:
– Sits against the intended vertical corner.
– Remains straight.
– Covers the vulnerable section.
– Is secured by the wrapping or strapping.
– Has not moved during pallet preparation.
– Uses a specification suited to the load.
– Eltete notes that Edgeboard selection should consider factors such as product weight, load height, stacking conditions and transportation environment.
6. Check the Pallet Condition
– Everything above the pallet depends on the platform underneath it. A well-wrapped load can still become unstable if the pallet itself is damaged or unsuitable. Before loading, inspect the pallet.
Look for:
– Damaged sections
– Weak areas
– Uneven surfaces
– Deformation
– Poor runner condition
– Unsupported product areas
– Incorrect pallet dimensions
– The pallet should also match the way the shipment will be handled.
– For example, manufacturers should consider whether two-way or four-way forklift access is required and how the unit will move throughout the logistics process.
– Eltete recommends selecting pallet systems according to the product, required handling method and destination rather than considering pallet dimensions alone.
– Product and Pallet Should Work Togethe. A pallet should not simply be added after the product packaging has already been decided. Both should be considered together.
Manufacturers should check:
Q – Does the load fit correctly?
Q – Are all important areas supported?
Q – Can the forklift enter correctly?
Q – Are there concentrated loads?
Q – Is the pallet strong enough for the application?
Q – Is the load suitable for stacking?
– The supporting platform is part of the transport packaging system.
7. Check What Happens During Movement
– The final check should not happen while the pallet is completely stationary. Transportation involves movement.
A load that appears stable on the factory floor may behave differently when it is:
– Lifted by a forklift
– Turned
– Stopped
– Moved across an uneven warehouse floor
– Loaded into a truck
– Transported over a long distance
– Eltete notes that unstable loads may shift, lean or collapse during forklift handling and transportation. This is why manufacturers should evaluate the complete load under realistic handling conditions before using a new packaging configuration regularly.
– Conduct a Handling Trial
– For a new load design, consider moving the pallet through the normal warehouse process.
Observe whether:
– The cartons remain aligned.
– The Edgeboards stay in position.
– The wrapping remains secure.
– The straps maintain tension.
– The load begins to lean.
– The products move internally.
– The pallet remains undamaged.
– Eltete also recommends conducting handling trials when evaluating packaging systems for demanding loads. If a problem appears during the trial, investigate the cause. Do not automatically solve every movement problem by adding more wrapping or more straps.
Q – What Causes Pallet Loads to Become Unstable?
A – There is rarely only one cause.
Common factors can include:
– Poor carton alignment
– Uneven weight distribution
– Weak outer cartons
– Incorrect pallet dimensions
– Pallet overhang
– Too much empty space
– Insufficient internal support
– Incorrect strapping tension
– Poor wrapping
– Missing corner reinforcement
– Damaged pallets
– High load height
– Movement during handling
– The complete transport packaging system should therefore be reviewed together. Fixing only one component may not solve the actual problem. Do Not Use More Packaging Without Finding the Cause
When businesses experience transport damage, the easiest reaction can be to add more material.
– More film.
– More straps.
– More cardboard.
– More cushioning.
– But this can increase packaging use without solving the problem. For example, if cartons are moving because they do not fit the pallet correctly, adding another strap does not correct the pallet dimensions.
– If the corner is being crushed because of concentrated strapping pressure, applying even more tension may make the problem worse. Eltete’s guidance recommends identifying the root cause of transport damage rather than simply adding more packaging material.
The objective should be:
– Right material. Right position. Right amount.
– Pallet Stability Is More Than External Packaging
– Manufacturers should also consider what is happening inside each carton.
– A pallet may remain perfectly upright while the product inside the package moves.
– Empty internal space can allow products to hit the sides or corners of the box during transportation.
Depending on the product, suitable internal packaging may include:
– Honeycomb Board
– Dividers
– Partitions
– Paper-based cushioning
– Void fillers
– Custom inserts
– Support components
– Eltete notes that internal packaging should hold the product securely while avoiding unnecessary pressure or excessive material. Good pallet stability therefore begins with the product itself and continues outward through the box, pallet and securing system.
A Simple 7-Point Pre-Shipment Check
Before the pallet leaves the warehouse, ask:
1. Alignment
Q – Are the products correctly aligned with no unnecessary overhang?
2. Weight Distribution
Q – Is the load balanced and properly supported?
3. Strapping
Q – Are the straps positioned and tensioned correctly?
4. Wrapping
Q – Does the stretch film securely unitise the load?
5. Edgeboard
Q – Are vulnerable corners reinforced and protected?
6. Pallet Condition
Q – Is the supporting platform suitable and undamaged?
7. Handling Movement
Q – Does the load remain stable when lifted and moved?
– If one of these areas fails, the shipment may need further review before dispatch. Stable Loads Start Before the Truck Arrives
– Pallet load stability should not be treated as the final step of packaging.
It begins when the manufacturer decides:
– How the products will be packed.
– How the cartons will be arranged.
– Which pallet will be used.
– Where reinforcement is needed.
– How the load will be secured.
– How it will be handled.
– The strongest result usually comes when these elements are designed together.
– Eltete Malaysia’s Transport Packaging Solutions approach combines products such as Edgeboard, Paper Pallets, Slip Sheets, Wrap Around profiles, Honeycomb Board and suitable securing materials according to the application.
– The objective is not simply to use more packaging. It is to create a transport unit that provides the required support, protection and stability throughout the logistics process.
Q – Is Your Pallet Load Ready to Ship?
A – Before releasing your next pallet, look beyond whether the stretch film appears tight. Check the complete load.
Q – Is it aligned?
Q – Is the weight supported correctly?
Q – Are the straps applying the right pressure?
Q – Are the corners protected?
Q – Is the pallet suitable?
Most importantly:
Q – What happens when the load starts moving?
A – Finding these problems before shipment is easier than dealing with damaged goods after delivery.
– For manufacturers experiencing unstable pallet loads, crushed corners, product movement or recurring transport damage, Eltete Malaysia can evaluate the packaging configuration and recommend suitable paper-based transport packaging components according to the product, load, handling method and destination.
Learn more at www.eltete.com.my
