Load Planning Archives

Container Planning Guide: Maximize Space and Efficiency

December 10, 2024/in Container Planning, Load Planning, MagicLogic/by Marilyn Bunderson

The world is a lot smaller than it used to be. Essential items we use daily have a travel history, and many have spent a little time hanging out in a shipping container. It’s estimated that 80% of goods worldwide are transported via the sea—or about 1.95 billion metric tons annually—from your favorite jacket to the phone in your hand and even the car you drive. That translates to a lot of shipping containers on the move at any given moment, with the requisite container planning, of course, to keep things running smoothly.

What is container planning?

A standard shipping container is 8 feet 6 inches tall and 8 feet wide (a high cube container is a foot taller). Containers are typically 10 feet, 20 feet, or 40 feet long. Internal storage space for a 20 foot container is roughly 1100 cubic feet, or about the contents of a three or four bedroom house. That’s a lot of space, and filling it properly can get complicated!

Why effective container planning matters

Sending goods across the ocean in shipping containers may feel a bit like sending your child off to college—with only so much you can control. However, having a packing blueprint in place allows workers all along the supply chain to pack your items correctly into boxes and pallets and then load them properly into the shipping container. Proper planning will make a huge difference in a variety of ways.

Reduce shipping costs

That’s right. Packing efficiently will reduce your shipping costs. You want to use as much of the available space as possible to reduce the number of containers you need to fill. If you have a variety of sizes, shapes, and weights, it becomes all the more complicated. Efficient container planning helps you maximize the container’s space, ensuring fewer empty gaps and lowering costs by cutting down on the number of containers needed.

Improve efficiency

I recently went on a trip to Peru—what a beautiful country! I brought along quite a few things for some friends there. I must have packed and unpacked my suitcase at least five times as I tried to fit in as much as I could and still stay within weight limits for the airline. Most warehouse workers don’t have the time or energy to figure out the most efficient way to load a storage container. If they have a plan, they can move swiftly and get things loaded and on their way quickly, which improves overall supply chain efficiency and keeps your operations running smoothly.

Avoid damage

The optimal arrangement of goods within a container takes into account the safety of the product. Fragile items must be secured appropriately and weight distributed evenly to prevent shifting during transit. With the right container plan, items are less likely to sustain damage, reducing the risk of costly returns or customer dissatisfaction.

Minimize the environmental impact

Optimizing container space allows you to reduce the number of shipments required, which directly lowers carbon emissions and fuel consumption. And if you want to align your business with eco-conscious goals, you can minimize your environmental footprint by shipping fewer, fully packed containers. Plus, fewer containers mean less plastic and packaging waste, which is better for the environment.

Key elements of successful container planning

So what does it take to successfully plan your container load? More elements are involved than you may think.

Space optimization: Not to put myself on repeat, but it’s essential to use as much of the container’s space as possible. Arranging your goods carefully will minimize unused space (so you’re not paying to ship air across the ocean), reduce the number of containers you need, and subsequently reduce your transportation costs. Software solutions like Cube-IQ will help you calculate the best arrangement for different products to maximize space.
Load balancing: Distributing the weight in the container will help prevent damage and maintain the stability of the load as it moves across the ocean. Generally, that means heavy items at the bottom, lighter items at the top–makes sense, right? It’s also important to ensure an even balance so the container doesn’t tip or shift easily.
Regulation compliance: As you’re well aware at this point, moving goods from one place to another—especially across borders—means complying with regulations such as weight limits, customs documentation, and cargo securing standards. These requirements must be factored into the planning process so your shipments meet international standards and avoid delays or fines.
Protecting your goods: If the goods you’re transporting are either fragile or temperature sensitive, your container planning takes on a new level of complexity. Make sure you take into account the need to properly cushion fragile items to prevent breakage. You can also place the goods within the container in ways that prevent exposure to unfavorable conditions.
Efficient loading sequences: At this point you have several considerations to keep in mind as you’re planning your container loading. To load it efficiently, you can plan the order in which items are placed in the container. This will ensure that you have easy access to goods that need to be unloaded first and will minimize the time spent loading, unloading, and handling.
Sustainability considerations: Proper loading of your goods will help you avoid using an excessive amount of packing material. This reduces waste and carbon emissions. You’ll also reduce the number of shipments necessary to transport your goods—something that’s good for the environment and your pocketbook.
Communication and collaboration: Having a plan in place allows for better communication and collaboration from one end of the supply chain to the other. From suppliers to warehouse workers and logistics teams, communication is crucial to ensure everyone involved understands the plan and can make adjustments as necessary to keep your goods safe.

How to execute effective container planning

Before you get overwhelmed, let’s break container planning down into three simple steps. As you follow these steps, make sure to implement safety and compliance measures along the way and make adjustments as necessary as the need arises.

Step 1: Assess your cargo

You’ll need to know the details of your cargo before you start your plan. That means you have to know the size, shape, weight, fragility, and special handling requirements of your items. That way you’ll understand the constraints or special considerations you’ll need to keep top of mind such as temperature control, stacking restrictions, etc. that influence how the goods are packed and shipped.

Step 2: Choose the right container type

Knowing the characteristics of your cargo will inform your choice of container. Of course the first basic consideration is how big it should be. But this could also include whether you need a dry container, a refrigerated container, an open-top container, or some other specialized container. Choosing the right container will make your loading process more efficient.

Step 3: Optimize loading patterns

This step refers to how you arrange your goods within the container. You want to maximize space, minimize damage, and ensure stability and safety during transit. Consider how each item is placed, weight distribution, stability, vertical stacking, and even grouping of items. It’s a lot. Load planning software would be helpful in every step of the process and in meeting the elements relevant to your goods. That said, planning software is especially helpful in optimizing your loading patterns.

Benefits of container planning software

I’ve mentioned it a few times, but it’s worth repeating. Container planning software will solve all your problems. Okay, it’s probably not going to solve your personal problems. But when it comes to shipping containers, it’s certainly going to make your life much easier. Let’s go through a few benefits of using software to handle your container or load planning.

Optimized use of space

Advanced algorithms in container planning software calculate the best arrangement for your goods in the container, helping you to maximize the available space. The software makes sure that every inch of the container is used efficiently, which reduces the number of containers you need and reduces the overall shipping cost.

Faster planning and execution

Software thinks faster than we do. Load your information into the system (this is done automatically through direct integrations), and you’ll have the right plan in your hands in a fraction of a second. Your team will be more efficient as they follow the plan. They won’t need to worry about trying to think it through themselves.

Cost savings

When you ship large quantities of goods, it multiplies the savings you’ll experience when you fit your products into the right size boxes and the right size containers. You can read how FabFitFun saved millions in shipping each quarter or how Toysmith saw a 12% to 15% increase in revenue per carton. The planning pays off in measurable ways that will impact your bottom line. Optimizing your space, reducing the number of containers you need, and helping your labor force be more efficient (saving time and money) adds up quickly.

Reduced risk of damage

The software will tell you the best way to pack your goods, and that will keep them safer. Full stop. It will calculate stacking patterns that ensure your fragile items are placed in safe, stable positions and that the weight is evenly distributed. This will help keep your cargo from shifting during transport.

Improved accuracy and operational efficiency

Despite best efforts, manual loading can lead to mistakes. Container planning software reduces error with precise measurements, exact weight distributions, and optimal loading configurations eliminating the need for “best guessing.” Along with accuracy, eliminating the need to manually make loading decisions will speed up the process, contributing to overall operational efficiency.

Regulatory compliance

Your planning software can ensure that shipments comply with regulations like weight limits, cargo securing methods, and customs requirements, and this is accomplished automatically. Your business will avoid fines, delays, and other compliance related issues. Some software can also generate the needed documentation for international shipments.

MagicLogic container planning

MagicLogic’s load planning software is a game changer for container planning. Using advanced algorithms to maximize the use of space and optimize load configurations, MagicLogic helps companies reduce shipping costs, minimize the number of containers required, and increase operational efficiency. Our product will ensure that you’re using every inch of your container effectively, turning around plans in under 100 milliseconds, handling mixed loads, and reducing the risk of transport damage.

Try it free!

Frequently asked questions (FAQs)

What is container planning, and why is it important?

Container planning is the process of optimizing the use of shipping containers. It means figuring out the best way to arrange goods in a container to maximize space, reduce waste, minimize cost, and keep the products safe during transit. Container planning is important because it helps businesses load containers more efficiently, lowers shipping and labor costs, minimizes the risk of damage to goods during transport, and supports sustainability efforts.

How does container planning software improve efficiency?

Container planning software automates the process of loading a container so it’s both faster and more accurate than manual loading. Advanced algorithms calculate the best way to pack the goods into the container based on size, shape, and weight. Because it’s automated, less time is spent during the loading process, human errors are minimized, and the process saves money and time.

Can these tools handle different container sizes and types?

Yes, container planning tools can handle different container sizes and types. Whether you’re using standard containers, refrigerated containers, open-top containers, or specialized containers designed for hazardous materials, the software will plan your ideal load based on specific requirements. With planning software, businesses can handle a variety of containers with no problem, ensuring goods are delivered safely.

Forklift loading two pallets onto a truck

Planning Your Load: How Many Pallets Fit in a Truck?

August 20, 2024/in Load Planning, MagicLogic, Palletization/by Marilyn Bunderson

Are you paying for air?

If loading pallets into a truck feels like a high-stakes game of Tetris, you’re not alone. The trouble is, when you’re loading pallets into trucks, every square inch counts. If you’re not maximizing your space, you’re essentially throwing money away. All those gaps and pockets of air inside your trailer might not seem like much at first glance, but they add up to significant inefficiencies such as higher fuel costs, more trips, and wasted resources.

And when margins are razor-thin, you can’t afford to pay for space you’re not using.

Unfortunately, inefficient loading doesn’t just cost you extra in shipping fees; it can lead to damaged goods and increased liability. Poorly packed trailers are more prone to shifting loads, damaged goods, accidents, or fines. On the flip side, mastering load planning can transform your logistics—reducing costs, improving safety, and boosting your bottom line.

Let’s dive into some strategies that will help you load your pallets like a pro, minimizing that wasted space, lowering your transportation costs, and ensuring your goods arrive safely to their destinations. Let’s make sure you never heave to pay for air again.

How many standard pallets are in a full truckload?

On average, a 53 foot semi trailer can fit 30 standard pallets, assuming they aren’t stacked. However, this number can vary significantly based on several factors:

Pallet size: A 48” x 40” GMA (Grocery Manufacturers Association) pallet is standard, but other pallet sizes may be used, and that affects how many will fit in a trailer.
Loading configuration: The pallets can be loaded straight (end-to-end lengthwise), pinwheeled (one lengthwise then one crosswise), or turned (end-to-end crosswise). This will affect how many will fit.

Pallet weight: The overall weight of the pallets and their contents may limit the number of pallets due to weight restrictions on the truck.

Stacking: If the pallets can be safely stacked, the number of pallets per truckload can increase up to double.
Axle configuration: The specific axle configuration of the truck can influence how the weight needs to be distributed, which will impact how many pallets can be loaded.

To provide a more precise estimate, refer to the following table that assumes the use of standard 48” x 40” GMA pallets, loaded without stacking.

Trailer Length	48” x 40” GMA Pallet
53 feet (636 inches)	26 straight 28 pinwheeled 30 turned
48 feet (576 inches)	24 straight (tight) 26 pinwheeled (tight) 28 turned
40 feet (480 inches)	18 straight 20 pinwheeled 22 turned
24 feet (288 inches)	10 straight 12 pinwheeled 14 turned
16 feet (192 inches)	6 straight 8 pinwheeled 8 turned

What are standard pallet sizes?

The 48” x 40” pallet is the most common size in the U.S. and Canada. Referred to as the GMA pallet, the dimensions were standardized by the Grocery Manufacturers Association, and the pallet is generally used for groceries and warehousing.

Though 39% of pallets used in the U.S are custom sized, many other sizes are common throughout North America:

42” x 42” or paint pallet, it’s frequently used in the telecommunications and paint industries
48” x 48” perfect for transporting 55 gallon drums of liquid
48” x 42” used by the chemical and beverage industries
48” x 45” used in the automotive industry
40” x 40” common in the dairy industry
36” x 36” often used to transport bottled beverages

In Europe, pallet sizes are measured in millimeters, and the most common sizes are the EUR (1200 mm x 800 mm—also known as EUR 1, Europallet, and EPAL), the EUR 2 (1200 mm x 1000 mm—similar in size to the GMA pallet common in North America), the EUR 3 (1000 mm x 1200 mm), and the EUR 6 (800 mm x 600mm).

How to maximize trailer space

Remember that air space you don’t want to pay for? It’s crucial to maximize trailer space to improve efficiency, get rid of that air space, and reduce shipping costs. To make the most of every inch, consider carefully how your goods are loaded, keeping in mind factors like stackability, pallet size, and the order in which items are placed in your trailer. This will also enhance the safety and security of your cargo during transit.

These tips and strategies will help you maximize your trailer space effectively:

1. Stack your pallets when possible. Using the vertical space is more efficient, but if you do, it’s critical to make sure the items on the pallets are stable and secure to prevent shifting or damage during transit. Stacking properly can double the number of pallets you can fit into your trailer.
2. Opt for uniform pallet sizes that maximize available space. If possible, use smaller pallets for smaller shipments, which will help you be more efficient with your arrangement and reduce wasted space. Keep the configuration of different pallet sizes in mind to optimize loading patterns.
3. Load large and heavy items first. Placing larger and heavier items at the back of the trailer and on the bottom of the stack helps balance the trailer for safer driving. It also ensures that heavier items are securely positioned and less likely to cause damage to lighter, more fragile goods.
4. Load small and light items last. Seems like a no brainer, but it’s worth pointing out that filling in gaps with light and small items will ensure that no space is wasted. These items can be placed on top of heavier goods or in spaces between pallets to maximize every inch of your trailer.

A note about weight distribution: Proper weight distribution within the trailer maximizes space but also maintains safety on the road. Unevenly distributed loads can lead to increased wear on tires, reduced fuel efficiency, and dangerous driving conditions. It’s never okay to sacrifice proper weight distribution for the sake of saving space. It’s not worth it in the long run. Make sure you understand axle weight limits, where the center of gravity needs to be, and how to avoid improper loading that could lead to accidents or fines during inspections.

Still having issues with loading your pallets? Read these solutions to 15 common load optimization problems.

The cost of inefficient loading

One of the biggest challenges in logistics is making sure each load is as cost effective as possible. Inefficient loading means wasted space and increased transportation costs, and nobody wants that. If you aren’t using your space efficiently—if your trucks aren’t fully optimized—you’re essentially paying to transport air. That jacks up fuel costs and increases your carbon footprint unnecessarily. On the flip side, higher efficiency with loading your pallets into your trucks will save on shipping costs, reduce fuel charges, and help the environment.

Make load planning easy

Properly loading your pallets and placing them efficiently into your trucks will keep your goods safer and reduce shipping and transportation costs significantly. These tips in this article will help, but you don’t have to figure it all out on your own. The easiest way to plan your loads quickly, efficiently, and safely is to use load planning software like Cube-IQ. Our advanced load planning software is designed to handle the complexities of modern logistics so you don’t need to break a sweat.

How does it work? Cube-IQ communicates with your other systems, plugging in all pertinent information about individual items and specific packaging rules you have in place. Our algorithm then automatically determines the optimal plan for the situation, whether you’re packing items into a carton, on a pallet, or into a truck.

Cube-IQ plays the perfect game of Tetris so you can pack efficiently and safely, saving time, energy, and money in the process.

Start your free trial today!

Load Planning, Cartonization and Palletization Now Accessible in the Cloud

November 9, 2022/in Load Planning/by Trevyn Meyer

MagicLogic load planning software is now available in the Cloud for customers. It is suitable for companies looking for a SaaS solution without any additional overhead on local IT resources. Customers who prefer to purchase licenses outright still, of course, have this option.
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Cube-IQ Web and BlackBox are both available as subscription-based services, securely hosted on our servers using Microsoft Azure. Logistics service providers, retailers and manufacturers can now plan loads efficiently, directly from the Cloud. Both applications give accurate results at lightning speed using our advanced algorithms.
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Cube-IQ Web – All the Same Functions of Cube-IQ

With Cube-IQ Web, our subscription holders can log into the service wherever they use their tablet, laptop or phone. Cube-IQ is renowned for covering more operational requirements than any other software. It can handle even the most complicated loading rules, allowing planners to choose the position and orientation of each item loaded into a container, railcar, truck or ULD.
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Cube-IQ optimizes loading into one or more containers, automatically selecting the correct-sized container for each load and ensuring more items are loaded every time. A built-in database ensures no other external software is required. The graphical user interface allows load planners to edit loads on the fly, step through loading plans, and view them from any angle, thanks to a powerful graphics engine. Frequently used recipes can be saved for future calculations.
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Many trucking companies fall foul of strict laws on axle weights. Cube-IQ ensures all axle weights are accurately calculated, so loads are safe and legal. Other options include loading in a pick or drop sequence, and the software can easily handle split-level trucks or trailers.
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BlackBox – Cartonization

Many companies still struggle with items packed and shipped in incorrectly sized cartons, wasting cardboard and using excess dunnage, and significantly increasing shipping costs. Our Cartonization software eliminates this problem, using item dimensions and weights to select the optimally sized carton in near real-time, ensuring this solution is ideal for eCommerce. Warehouse staff receive clear loading plans, and the software is also suitable for use with robotic pack stations. Customers receive perfectly packaged goods with only enough fill material to protect the items and ensure they arrive in immaculate condition, so returns are minimized due to damages.
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BlackBox works behind the scenes and is specifically designed to integrate easily with all WMS/ERP systems using industry-standard APIs.
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BlackBox – Palletization

True mixed palletization is tricky to achieve, and BlackBox has a separate optimization engine developed specifically for this purpose. Solutions include complex mixed-case pallet stacking and palletization for manual or robotic pack stations. Our software ensures your pallets are loaded accurately, calculating cartons’ strength and crush resistance and ensuring only lighter items are placed on top. BlackBox ensures no cartons or items overhang the pallets or the layers underneath, based on the item’s precise weight and dimensions. Hence, pallets are stable, can be wrapped securely, and are ready for shipping or warehouse storage.
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Easy integration and software training ensures Cube-IQ or Blackbox is ready to use quickly. With a subscription, your company starts saving money from day one with minimal initial outlay. Subscription prices are tailored to meet the demand of each company and can be scaled up as your business grows. Interested? Contact us for more information and a software demonstration.

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Air Freight Logistics: Loading ULDs Efficiently

March 31, 2022/in Load Planning/by Trevyn Meyer

Air freight logistics has become more challenging over the past year. Like so many industries, it has needed to adapt rapidly to changing circumstances. While previously, much of the industry was B2B, it has increasingly become more business-to-consumer oriented. The freight industry has also needed to compensate for the loss of cargo space.

Previously, a lot of cargo was transported in passenger plane holds, but the decline in travel has led to commercial flight cancellations of around 50%. Airlines have adapted to the challenge, repurposing passenger planes to carry more freight. While some continued only to offer space in the hold, others have gone a step further, removing seats to carry more freight, but this means the freight must be packed directly into cartons rather than into Unit Load Devices or ULDs. Despite these adaptations, the lack of cargo space remains challenging, and air freight rates have increased significantly in response.

With increased freight costs, the need to optimize loads correctly and safely is even greater. MagicLogic has years of experience in air freight logistics, optimizing ULDs efficiently and safely, saving time and money.

Optimizing ULDs

ULDs are exceptionally tricky to load efficiently, as there are numerous variations in sizes and shapes; they are not rectangular and have cut-off corners or ceilings. The shape depends on where the ULD is to be loaded in the plane and the type of aircraft. Then there is the actual load to consider. Some cargo is pre-loaded into cartons or boxes, while other loads need to be built on open pallets. These pallets must be built to fit the contour of a specific ULD. Once built, they are secured in place by a net fitted around the rim of the pallet.

Following Loading Rules

If cartons are used, our software ensures they are packed correctly, protecting the cargo and ensuring it arrives in perfect condition. When pallets are loaded, it is important to ensure the weight of the cargo is not concentrated on a single pallet. Accurate load spreading is essential in making it easier to load the ULD, and to help balance the aircraft.

MagicLogic load optimization software follows the strictest and most complex loading rules, ensuring pallets or cartons are loaded safely and stably. Loading rules are fully customizable, including the orientation of each item and its allowed location in a load. This ensures a delicate item is never loaded on the bottom and that goods that require specialized handling are packed correctly. The software calculates an optimized pallet or carton’s weight, ensuring it does not exceed safe levels.

As the pandemic begins to ease with the introduction of vaccines, the airline industry will gradually return to normal, and the number of flights for passengers and cargo will increase. However, it could leave behind some fundamental changes to shopping habits. People have become accustomed to the convenience of purchasing goods online, changing air freight logistics for good.

Choosing the Best Load Optimization Software

Companies with limited loading of ULDs can use our Cube-IQ® software program. Those companies who routinely send large amounts of sir freight will benefit from our BlackBox® optimizer, which provides high-speed Cartonization and advanced mixed-palletization.

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