A product can be packed correctly and still arrive damaged. Sometimes, the problem does not happen inside the truck, container or aircraft. It happens before the shipment even leaves the warehouse.
Forklifts are essential for moving palletised goods, but incorrect handling can damage cartons, pallets and the products inside them. Forks may hit the side of a load. Pallets may be dragged instead of lifted. Cartons may extend beyond the pallet. Loads may also become unstable after repeated movement around the warehouse.
For manufacturers and exporters, reducing forklift damage starts with looking at both packaging design and handling practices.
1 – Where Does Forklift Damage Usually Happen ?
– A shipment may be handled several times before reaching the customer.
– Forklift handling can happen during:
– Movement from production to warehouse
– Palletising
– Warehouse storage
– Loading into trucks
– Container loading
– Distribution centre handling
– Customer unloading
– Every movement creates another opportunity for impact, incorrect lifting or load movement. This is why transport packaging should not only be designed for transportation. It should also be designed for handling.
1. Forks Hitting the Cartons
– One of the most visible types of forklift damage happens when the fork tips hit the load instead of entering the pallet correctly.
This can result in:
– Punctured cartons
– Crushed products
– Damaged lower boxes
– Torn packaging
– Broken internal components
– The risk becomes higher when cartons are positioned too close to the forklift entry area.
2 – How to Reduce the Risk
– The load base should provide enough clearance for the forks to enter correctly. Operators should also be able to clearly identify the correct forklift entry direction.
– When using a Paper Pallet, the design should match the required handling method. Eltete Paper Pallets can be developed in different configurations, including two-way and four-way pallet designs depending on the application.
– The correct design should consider:
– Fork dimensions
– Entry direction
– Product weight
– Pallet dimensions
– Load distribution
– Warehouse handling method
– Packaging design and forklift operation should be considered together.
2. Cartons Extending Beyond the Pallet
– Pallet overhang happens when part of the carton or product extends beyond the pallet base. This leaves the outer section of the load unsupported.
– It also exposes the packaging to forklifts, other pallets, warehouse racking and nearby loads. A small impact may crush the carton corner or damage the product inside.
2.1 – Better Approach
– Where possible, cartons should remain within the footprint of the load platform. Manufacturers should compare:
– Product dimensions → Carton dimensions → Pallet dimensions
– before selecting the pallet size. A custom-sized load platform may sometimes provide a better fit than forcing a product onto an unsuitable standard pallet.
– Eltete Paper Pallets can be customised according to product and transport requirements.
3. Forks Entering at the Wrong Angle
– Forklift forks should enter the pallet opening correctly. If the forklift approaches at an angle, one fork may contact the pallet structure, carton or product.
– This may:
– Damage the pallet
– Push the load sideways
– Tear packaging
– Affect load alignment
– Make the shipment unstable
– Repeated incorrect handling can create damage even when the first impact looks minor. Operators should approach the load straight and ensure the forks are correctly positioned before lifting.
4. Dragging the Load Instead of Lifting It
– A pallet should normally be lifted before it is moved. Dragging a loaded pallet across the warehouse floor creates additional stress on the load base.
– It may damage:
– Pallet runners
– Bottom boards
– Corners
– Packaging material
– Products near the base of the load
– The problem can become worse when the floor is uneven. The correct load platform should also be selected according to the expected warehouse environment and handling process.
– Eltete states that its Paper Pallets are designed with PallRun® pallet feet and can be developed according to different product, handling and destination requirements.
– However, good packaging should still be supported by correct forklift handling.
5. Forklift Impact on Pallet Corners
– The lower corners of a shipment are especially exposed in busy warehouse environments.
– A forklift may accidentally hit the corner while:
– Turning
– Positioning another pallet
– Entering a rack
– Moving through a narrow aisle
– Loading a truck
– Even when the product is not directly hit, corner damage can affect the structure of the complete palletised load. A crushed corner may also affect the position of Edgeboard, stretch film or strapping.
6 – Protecting Vulnerable Corners
– Eltete Edgeboard can be positioned vertically along the outer corners of palletised goods. The profile provides additional corner protection and can also support palletisation, stabilisation and unitisation.
– Edgeboard may be combined with stretch film or strapping depending on the application. The correct Edgeboard strength should be selected according to the load rather than using one specification for every shipment.
6. Incorrect Fork Position Under the Load
– Forks should support the load correctly before lifting. If the forks are positioned too close together, too far apart or only partly inserted, the weight may not be distributed correctly. This can create stress around certain areas of the pallet.
– For heavy loads, weight distribution becomes especially important. Manufacturers should understand where the product actually transfers its weight onto the pallet. For example, a machine supported by four small feet creates a different load pattern from cartons that distribute weight across the complete pallet surface.
– The pallet design should therefore consider:
– Total load weight
– Support points
– Centre of gravity
– Weight distribution
– Fork position
– Handling direction
– Total weight alone does not provide enough information.
7. Lifting an Unstable Pallet Load
– The packaging may survive normal storage but become unstable as soon as the forklift starts moving. Acceleration, turning and braking can cause cartons to shift.
– A load with poor stability may:
– Lean
– Separate
– Slide
– Lose alignment
– Damage carton corners
– Put pressure on strapping
– The forklift operator may appear to be the cause of the problem when the real issue started with the load design.
7.1 – Improve the Complete Unit Load
– Manufacturers should review:
– Carton arrangement
– Weight distribution
– Load height
– Pallet dimensions
– Edge protection
– Stretch wrapping
– Strapping
– Internal support
– Eltete Edgeboard can be positioned on the vertical corners of the palletised load to support load stability and protect exposed corners. The packaging system should help the individual cartons move as one stable unit.
8. Forklift Damage to the Bottom Cartons
– The cartons closest to the pallet are often exposed to the greatest handling risk. Forks entering too high may hit the lower layer of cartons. Weak cartons may also become compressed when the load is repeatedly moved.
– Once the bottom layer becomes damaged, the cartons above it may begin to lean. This can affect the stability of the entire shipment.
8.1 – What Should Manufacturers Check?
– Look at the bottom layer after normal warehouse handling.
– Check for:
– Dents
– Punctures
– Crushed corners
– Tearing
– Carton deformation
– Uneven pallet support
– If the same area becomes damaged repeatedly, the issue should be investigated before adding more packaging. The real problem may be the pallet dimensions, fork entry, carton position or handling method.
9. Product Movement Inside the Packaging
– Not all forklift damage is visible on the outside. A carton may look normal while the product inside has moved. Sudden forklift movements may cause a poorly secured product to shift inside the package.
– This may lead to:
– Scratches
– Dents
– Broken components
– Product-to-product contact
– Damage to sensitive surfaces
– Internal packaging should keep the product in the required position throughout handling. Depending on the application, paper-based components such as Honeycomb Board may be used for functions including:
– Dividers
– Internal supports
– Product separation
– Weight distribution
– Surface protection
– Void management
– The internal design should be developed around the actual product.
10. Moving Loads Too Quickly
– Packaging cannot compensate for every handling mistake. Fast turns, sudden stops and aggressive lifting create additional movement. Tall or uneven loads are particularly sensitive.
– Operators should adjust their movement according to:
– Load height
– Load weight
– Product fragility
– Centre of gravity
– Pallet condition
– Warehouse environment
– A stable shipment should still be handled carefully.
– Packaging protection and operator behaviour work together.
– Packaging Damage Is Not Always a Packaging Problem
– When a damaged shipment is found, the first reaction may be:
“We need stronger packaging.”
– Sometimes that is correct. But not always. Consider a carton that is repeatedly punctured at the same height. Adding another layer of carton board may not solve the real problem. The actual cause could be incorrect fork positioning.
– The better process is:
– Identify the damage → Find where it happens → Understand the cause → Improve the correct part of the system
– Adding more packaging without understanding the problem may increase cost and material use without preventing the damage.
1 – How to Identify Forklift Damage
– Manufacturers can inspect damaged shipments and look for patterns.
2 – Puncture Near the Bottom
– Possible cause:
– Fork tip contacting the carton.
3 – Crushed Lower Corner
– Possible causes:
– Forklift impact, pallet overhang or incorrect pallet placement.
4 – Load Leaning After Handling
– Possible causes:
– Poor load stability, uneven weight distribution or aggressive forklift movement.
5 – Damaged Pallet Entry
– Possible cause:
– Fork entering at the wrong angle or height.
6 – Product Damaged but Carton Looks Normal
– Possible cause:
– Movement inside the packaging during forklift handling.
– Identifying the pattern can make the investigation easier.
7 – Review the Packaging at Different Stages
– Do not inspect the shipment only after it reaches the customer. Check it throughout the process.
– Stage 1: After Packing
– Is everything aligned correctly?
– Stage 2: After Palletising
– Does the product fit within the pallet footprint?
– Stage 3: After Warehouse Handling
– Are there any punctures, dents or crushed corners?
– Stage 4: Before Loading
– Is the load still stable?
– Stage 5: After Unloading
– Did the packaging remain in the same condition?
– This can help identify the stage where damage first appears.
– Train Forklift Operators
– Packaging improvement alone cannot prevent all forklift damage. Operators should understand the packaging they are handling.
– Important practices include:
– Use the correct pallet entry
– Approach the load straight
– Insert forks fully where appropriate
– Avoid hitting cartons
– Lift before travelling
– Keep the load stable
– Avoid sudden movements
– Follow the correct stacking method
– Report damaged pallets
– When a new packaging system is introduced, forklift operators should be included in the implementation process. For example, changing from a conventional pallet to a Slip Sheet may require completely different handling equipment and procedures.
11 – Test Packaging Under Real Handling Conditions
– A packaging design should not only look strong in a sample room. It should work in the actual warehouse.
– A practical trial can include:
– Pack the real product.
– Build the complete load.
– Move it using the normal forklift.
– Store it under normal conditions.
– Load it onto the usual transport vehicle.
– Unload it using the expected method.
– Inspect the packaging and product.
– Document any damage. Photos can also help identify recurring damage areas. The packaging can then be adjusted based on actual handling conditions.
12 – Questions to Ask Before Choosing a Pallet or Packaging System
– Before selecting transport packaging, provide the supplier with information such as:
1 – Product
– What is being transported?
– What are its dimensions?
– How much does it weigh?
– Is the weight evenly distributed?
– Where are the main support points?
2 – Packaging
– What outer packaging is currently used?
– Are the corners sensitive?
– Is internal protection required?
– Will the product be strapped?
3 – Handling
– What type of forklift is used?
– Which direction will the forks enter?
– Is a hand pallet truck used?
– Will the load be handled several times?
4 – Storage
– Will the product be stacked?
– Will it be placed on warehouse racks?
– How long will it remain in storage?
5 – Transport
– Is it shipped by road, sea or air?
– Is it a domestic or export shipment?
– How will the customer unload it?
– The more complete the information, the easier it is to develop packaging around the actual logistics process.
13 – The Goal Is Not More Packaging
– Reducing forklift damage does not always mean adding more material. The goal should be to use the right packaging design in the right places.
– A better solution may involve:
– Correct pallet dimensions
– Better forklift entry
– Stable carton arrangement
– Vertical Edgeboard protection
– Suitable internal support
– Proper load securing
– Better operator handling
– Good transport packaging should protect the product while also working efficiently with the warehouse and logistics operation.
14 – Final Thoughts
– Forklift handling is a normal part of manufacturing and logistics. The objective is not to eliminate handling. It is to design the packaging and handling process so that they work together.
– Manufacturers experiencing repeated packaging damage should look beyond the damaged carton.
– Review:
– Where did the damage happen?
– How was the load being handled?
– Was the load platform suitable?
– Were the cartons properly supported?
– Was the product stable?
– Understanding the cause makes it easier to improve the packaging without adding unnecessary material.
– Eltete Malaysia provides paper-based transport packaging solutions including Paper Pallets, Edgeboard, Honeycomb Board, Slip Sheets and customised packaging components that can be designed according to the product, handling method and transportation requirements.
For more information, visit www.eltete.com.my
