What is the Best Way to Maximize Space in Container Loads?

Efficient container loading is a critical part of reducing costs and optimizing logistics. When it comes to understanding container load basics and stacking pallets correctly, every detail matters when following key loading rules, and calculating weight-based costs. Learn how container-loading software simplifies the process, saves time, and helps ensure that you make the most of every shipment.

 

 

Global seaborne trade experienced a significant recovery in 2021, but that recovery was overshadowed by unprecedented port congestion. Major flashpoints emerged in the United States, Europe, and China, causing widespread disruption. In Northern Europe, shipping lines sought to improve efficiency by reducing the number of port calls per voyage.

In March 2024, container shipping from the Far East to the US West and East Coasts witnessed significant growth. Volumes on the West Coast route surged by approximately 24.20% to 942,442 TEUs, up from 758,557 TEUs in February. Similarly, the East Coast route saw a substantial increase of 22.56%, with volumes rising to 516,874 TEUs compared to the 421,673 TEUs the previous month.

These stats indicate many bottlenecks that may have a cascading effect, affecting various sectors involved in container shipping to destination warehouses.

Keeping in mind the latest changes in the market, we have prepared a complete guide to container loading for you. If you are in manufacturing, healthcare, electronics, or any other industry, we especially want to support you with our guidance and direct experience. You will learn about the principles of proper pallet stacking and container loading. We will show you how to increase productivity with modern container loading systems. Learn more about the container shipping industry and how to maximize your container space with our ultimate guide.

 

What is a container load?

A container load is the process of stuffing cargo on pallets or loose boxes into containers using forklifts and EPT (electric pallet trucks). The primary purpose of container shipping is intermodal transport which allows for the utilization of containers, shipping them overseas, and then transporting them by rail, road, or inland waters on a vessel. The last method of transportation is very popular in the Netherlands where cargo is unloaded from container ships in the port of Rotterdam and later transported by rivers to terminals such as the one in Venlo, a city in the Netherlands known for its logistics hubs.

 

 

Container shipping plays a vital role in the global economy. While road transport remains significant, the increasing focus on sustainability and the need to reduce carbon emissions are causing a shift towards more environmentally friendly modes of transport. European transport policy aims to reduce greenhouse gas emissions by 60% by 2050 compared to what greenhouse gas emissions were in 1990. A key strategy is to shift 30% of long-haul transport (more than 300 km) from road transport to rail and inland waterway transport, especially for containers and other ITUs.

This shift, combined with growing global trade, will further increase the importance of container shipping in the years to come. This is why it’s essential to be ready for even more cargo handled by intermodal transport.

 

How do you stack a pallet of boxes?

A container load starts with correct pallet stacking and often includes staging and later loading the pallets. Staging means putting one pallet on another in a way that will not damage the pallet underneath. In many cases, when we have different shipments, it might be appropriate to put one pallet on another if they’re not stacked too high. Later on, this article will drill more into the topic of proper usage of container space.

Here are a few steps on how to stack pallets:

• Do Not Use Damaged Pallets: Ensure all pallets are free from contamination such as dirt. Check for cracks or breaks, debris, or chemical residues as these can compromise product integrity.
• Place Heavy Boxes on the Bottom Layers: Heavy boxes should always form the foundation of your pallet stack to create stability and prevent crushing lighter items. Arrange them evenly across the pallet to distribute the weight uniformly. Avoid stacking heavier boxes too far to one side as this can cause tipping or instability during transport. Make sure the base layer is as flat and secure as possible before adding lighter items on top.
• Weight Distribution As a Whole: As we said above, minimize the mixing of heavy and light items in a single pallet load. You need to measure the maximum weight on each side. Place heavier boxes on the bottom of the stack when possible, but you also need to balance them on the pallet. This will help prevent the pallet from slipping or falling on its side once the forklift loads it into the container.
• Corrugated Orientation: Ensure that all boxes are stacked with the flute direction oriented vertically.
• Pallet Utilization: Maximize pallet space by fully utilizing the available area. Avoid any boxes that overhang beyond the edges of the pallet.
• Stack Height Control: Limit the overall height of stacked boxes and avoid double-stacking pallets whenever possible.
• Void Fill Optimization: Minimize space within cartons by using appropriate void fill materials and selecting the correct dimensions for the product. You can use carton scraps or airbags to prevent boxes on the pallet from moving after they are sealed.
• Avoid overhangs: Along with all of the others mentioned, prioritize the placement so that they do not go outside of the pallet. Moreover, avoiding overhangs can prevent the shifting of items during transport.
• Don’t Overuse Straps: Too many straps may prevent the use of conveyor belts to transport pallets around the warehouse. This is important to note when unloading, but also when stacking pallets. Edge protectors or edge guards should also be used to prevent plastic tape (straps) from damaging cartons.
• Column Stack Preferred: Whenever possible, opt for column stacking to maximize space utilization and ensure efficient loading and unloading operations. It is essential for pallet staging as you can provide a flat surface on top of the pallet to put another pallet on top.
• CBM Meters for Shipping: Finally, keep in mind that you need to load your pallets on a container or trailer. Therefore, the total amount of cubic meters (CBM) for a container or trailer needs to be calculated upfront so that its load capacity is not exceeded.

 

 

What are the main rules of container loading?

Several rules facilitate a correct approach to container loading. Regardless of the container’s dimensions, we must concentrate on the core principles of safe and efficient loading—ensuring balanced weight distribution, proper cargo handling, and strict adherence to regulatory standards.

This is not the only tip we have for you within this guideline. The best guides come from the biggest shippers involved in intermodal transport and sea shipping. These shippers include Maersk, Hapag-Lloyd, and many others. They always provide great manuals and container specifications that we want to follow so we choose the best possible way of shipping.

There are those involved in container engineering and maintenance who know the best way to load containers. They cover a wide range of standards and provide special containers to ensure you can choose the right equipment for your commodity and direction. Most than likely, they take care of the technical design for excellent durability and payload. We often refer to these guidelines to ensure you can better cope with industrial standards. For example, we may know where to place additional cargo safely through lashing points where you can secure cargo in bulk, etc.

The global container shipping industry experienced substantial growth in March 2024. Reefer container volumes increased by 12%, reaching 1,222,181 TEUs compared to 1,084,041 TEUs in the previous month. This significant growth reflects the continued demand for temperature-controlled goods and aligns with the positive trajectory of global trade.

Moreover, total container volume has significantly increased, rising 16% from 13,396,864 TEUs in the previous month to 15,560,078 TEUs in March 2024. These figures show a strong upward trend in container shipments worldwide.

The statistics above clearly provide a perspective on development for the container shipping industry. Later in our article, we’ll introduce how to cope with market needs for cargo shipping with containers by using loading platform software. However, before that, we should focus on the fundamental elements of container loading independent of any system. There is always a load of knowledge that your warehouse staff should keep in mind when loading containers.

In addition to the specific observations outlined in this article, the following essential requirements must strictly be adhered to for container shipments.

 

 

Key considerations for container loading (stuffing)

• Container Selection: Choose the most suitable container type to accommodate the cargo.
• Pre-Stow Planning: Develop a comprehensive pre-stow plan to ensure proper weight distribution. This planning phase is crucial for considering cargo volume, whether utilizing drayage trucking or any other type of transport while adhering to point loading limits. It’s essential to never exceed the container’s payload limits, ensuring that the combined weight of the cargo and container net weight does not surpass the container’s safe gross working load. Furthermore, strict adherence to all applicable road weight regulations during transit is mandatory.
• Weight Distribution: Distribute the cargo’s weight evenly across the container floor. Avoid concentrating heavy items in one section and light items in another. To ensure proper balance, adhere to the « 60% within half the length rule » for weight distribution.
• Cargo Handling: Never place heavy goods on top of lighter ones. Stow and secure all cargo tightly to prevent shifting during transit. Follow all handling instructions on cargo such as « Do Not Drop » or « This Side Up », to protect the goods from damage. Separate goods with sharp corners from softer merchandise using dividers and appropriate separating materials to minimize the risk of damage.
• Mixed Loads: When loading mixed cargo, prioritize safety by placing packages containing liquid cargo on the bottom tiers with dry cargo on top. For obnoxious cargo such as hides and carbon black, use cargo liners to prevent contamination and protect other goods.
• Loading Techniques: Avoid using clamps or other loading devices unless the goods can withstand them. For Dangerous Goods, strictly adhere to the IMDG Code packaging requirements to ensure safe transportation. Refrain from loading goods in a container with damaged packaging as this can compromise the safety and integrity of the cargo.
• Cargo Compatibility: Keep wet goods separate from dry goods to prevent moisture damage. Do not use dunnage or packaging that is incompatible with the cargo, which can lead to contamination or product damage. Separate sensitive merchandise from goods with strong smells to prevent tainting odors.
• Dangerous Goods Handling: Observe all regulations concerning hazardous cargo to ensure safe transportation. Use appropriate labels and placards to identify containers loaded with Dangerous Goods. Stow hazardous cargo near the door whenever possible for easier access and handling.
• Documentation and Safety: Include all necessary documentation for customs clearance and transportation. Record the seal and container numbers on all shipping documents for accurate tracking. Refrain from smoking, eating, or drinking during loading or unloading to maintain a safe and clean working environment.

 

 

An intriguing aspect of container shipping lies in the potential for specific ports to reach operational limits due to overloading. This risk of severe congestion, evident in ports like Barcelona, underscores the critical importance of effective container loading management.

In Barcelona, transshipment traffic surged dramatically, with increases of 22%, 64%, and 63% in January, February, and March 2024, respectively. This rapid growth highlights the potential for congestion. Similarly, other major ports experienced significant increases in traffic during the first quarter of 2024: Algeciras (7%), Valencia (18%), and Las Palmas (33%).

These figures emphasize the need for proactive measures to optimize container loading to prevent delays, not only for individual shippers but also for the overall efficiency of the global shipping network. By carefully managing container loading practices, we can mitigate the risk of congestion in major ports and ensure the smooth flow of goods worldwide.

 

What is less than container load shipping?

Less-than-container load (LCL) refers to ocean freight shipments that are too small to occupy an entire shipping container. To make these shipments cost-effective, they are combined with other smaller shipments from different customers within a single container.

This process, known as consolidation, allows for shared transportation costs and improved efficiency.

Here’s how it works:

1. Delivery and Consolidation: LCL shipments are initially delivered to a warehouse or a Container Freight Station (CFS). Here, they are carefully inspected and loaded into a shipping container alongside other LCL shipments from various customers.
2. Ocean Transport: Once the container is fully loaded, it’s handed over to an ocean carrier for transportation to the designated destination port.
3. Unloading and Separation: Upon arrival at the destination port, the container is transported to another warehouse or CFS. The consolidated shipment is carefully unloaded, and individual shipments are separated.
4. Inspection and Delivery: Each shipment is thoroughly examined to ensure it has arrived undamaged and complete. Finally, the individual shipments are delivered to their respective consignees.

 

Key advantages of LCL shipping

• Cost-effectiveness: Sharing container space significantly reduces shipping costs and reduces detention fees, compared to chartering an entire container for a small shipment.
• Flexibility: Suitable for smaller shipments that do not require the capacity of a full container.
• Convenience: Provides a convenient and efficient solution for shipping smaller volumes of goods internationally.

 

 

What is full container load shipping (FCL shipping)?

FCL, or Full Container Load, refers to ocean freight shipments in which a single shipper exclusively uses an entire shipping container for their cargo. FCL provides significant advantages, such as greater control over the transportation process, reduced risk of damage due to less handling, and potentially faster transit times compared to LCL. Shippers are responsible for the entire container’s cost, regardless of the space utilized, making it an ideal option for high-volume shipments.

While only 17 EU member states have significant freight transport by inland waterways, full container load shipping (FCL) is crucial in driving this sector’s growth. In 2022, the EU-wide unitization rate for inland waterway transport reached 9.2%, indicating a growing adoption of containerized transport despite a slight year-over-year decrease. The Netherlands led the way with the highest unitization rate at 12.9%, followed by Germany, Belgium, and France. FCL’s (FCL shipment) efficiency and cost-effectiveness for large shipments are key factors contributing to this trend, making it a vital component of modern inland waterway logistics.

 

What weight determines the cost?

Shipping costs for containers and trailers are calculated based on the chargeable weight, which is the higher end of the actual volumetric weight of your shipment. Volume weight considers the space your goods occupy during transport.

Shipping weight calculation

For each shipment, we determine and then calculate the chargeable weight, which is the higher end of both the actual weight (in kilograms) and the volumetric weight.

How to calculate volumetric weight (dimensions)

Volumetric weight considers the space a shipment occupies. It’s calculated by multiplying the package’s length, width, and height (in centimeters). This volume is then divided by a specific factor:

• Air Freight: 6,000
• Road Transport: 3,000
• Ocean Freight (LCL): 1,000

The exact factor may vary slightly depending on the carrier.

Ocean Freight Considerations

Ocean freight offers two options:

• Full Container Load (FCL): You rent the entire container exclusively for your use.
• Less-than-container load (LCL): Your shipment is combined with others in a shared container. In this case, you pay for the space your shipment occupies within the container.

What are the cost Considerations for Container Road Transport

We often use loading meters for trailers or containers to calculate costs for road transport. A loading meter represents one meter of floor space within the truck. This method is standard for goods that cannot be stacked efficiently.

• 1 loading meter typically equals 1.850 kilograms.
• 1 Euro pallet (80x120cm) is approximately 0.4 loading meters.
• 1 Block pallet (100x120cm) is approximately 0.5 loading meters.

 

Why use a container-loading software?

Among many solutions, there is one specific container load planning software, or as you wish to call it, container loading software. This system allows for the efficient loading of containers of any dimension. You will know directly if you have enough cargo for a certain container.

• Optimized Space Utilization: By accurately simulating the loading process, the software helps maximize the use of available space within the container. It minimizes wasted space and reduces the number of shipments required, leading to cost savings.
• Improved Load Stability: The software assists in creating stable and secure load configurations, minimizing the risk of cargo shifting during transit thus preventing damage. This ensures the safe arrival of goods and enhances customer satisfaction.
• Reduced Loading Time: The actual loading process becomes more efficient and faster with pre-planned loading arrangements. This streamlines operations and improves overall productivity.
• Cost Savings: Container loading software directly lowers transportation costs by optimizing space utilization and reducing the number of shipments.
• Enhanced Planning: The software provides valuable insights into load planning, allowing for better decision-making regarding container selection, route optimization, and resource allocation.
• Various vehicles and transport modes: you can use loading software to load van cargo on containers and trailers.

Based on industry studies and best practices from Xeneta, here are some potential quantifiable benefits from cargo loading software:

Maximize Container Space with Smart Loading

By utilizing Cargo Loading Software, businesses can achieve a 5-20% increase in container space utilization. This can be accomplished by taking the automated loading plans generated by the software and comparing them with traditional manual plans. Identifying and optimizing container space will ultimately lead to significant savings on shipping costs.

Accelerate Loading and Unloading for Increased Efficiency

Experience a 10-25% reduction in loading/unloading time by implementing Cargo Loading Software. Tracking loading times before and after software implementation allows businesses to quantify the time-saving benefits, increasing efficiency and reducing labor costs.

Reduce Transportation Costs with Optimized Loading

Cargo Loading Software can contribute to a 3-10% reduction in transportation costs. Businesses can directly observe the financial impact of optimized loading practices by analyzing shipping costs before and after software implementation while considering factors such as fuel consumption, labor costs, and the number of shipments.

Minimize Cargo Damage with Precise Loading

Reduce cargo damage by 5-15% through the implementation of Cargo Loading Software. Tracking cargo damage claims before and after software implementation demonstrates the software’s effectiveness in reducing damage incidents, leading to lower insurance costs and improved customer satisfaction.

 

Summary for loading shipping containers

Optimizing every aspect of the supply chain is critical to success in today’s competitive logistics landscape for container shipping. When implementing container loading software, companies can significantly increase operational efficiency, reduce costs, and minimize risk by maximizing container space. This will lead to speeding up loading times and allow you to reduce transportation costs and minimize cargo damage. There are many benefits in play.

Are you ready to unleash the full potential of your supply chain? Contact us today for a free consultation to learn how cargo-loading software can transform your logistics operations.

 

FAQ

How can cargo-loading software save money?

Freight loading software saves money by optimizing container space, reducing the number of shipments needed, and minimizing labor costs associated with manual loading. This translates into lower fuel costs, fewer trucks on the road, and lower labor costs. Additionally, minimizing cargo damage reduces insurance costs and avoids costly product replacements or repairs.

Is freight-loading software difficult to implement?

No, freight loading software is designed with ease of use in mind. Most systems offer intuitive interfaces and require minimal training, making integration into existing workflows relatively seamless.

What data does the software require?

Freight loading software typically requires data such as cargo dimensions and weight, container dimensions, and shipping routes and destinations. This information allows the software to accurately calculate optimal loading configurations and generate efficient transportation plans.

How can Cargo-Loading Software help sustainability?

Cargo loading software contributes to sustainability by optimizing loading and reducing the number of shipments required. By maximizing container space, companies can minimize the number of trucks on the road, leading to lower fuel consumption and carbon emissions. This is in line with growing environmental concerns and can improve a company’s image as an environmentally conscious organization.

How can I measure the return on investment (ROI) of my freight-loading software implementation?

The ROI of cargo-loading software can be measured by tracking key metrics such as reduced transportation costs, reduced loading/unloading times, reduced cargo damage claims, and improved container space utilization. By comparing these metrics before and after implementing the software, the financial benefits can be quantified and a clear return on investment can be demonstrated.