Load Planning Archives

What Is a Containerized Load? Types, Benefits and Challenges

February 25, 2025/in Container Planning, Load Planning, MagicLogic, Palletization, Supply Chain/by Marilyn Bunderson

Understanding containerized loads

A containerized load refers to goods packed into a standardized shipping container for transport via truck, rail, or ocean freight. These containers ship securely and simplify handling, reduce the risk of damage, and improve efficiency across the supply chain. Unlike loose cargo, containerized loads are packed according to specific weight distribution to minimize both transport costs and delays.

Containerized shipping has been around for decades, and today, most freight—whether it’s electronics, apparel, or industrial equipment—is transported in containers. However, optimizing these loads isn’t just about stacking products inside a metal box. Intelligent load planning will help you maximize space while maintaining stability, preventing damage, and meeting carrier requirements.

Types of containerized loads

Containerized loads come in various forms, depending on the shipment size, cargo type, and transportation requirements you face. And in order to choose the right shipping method, you should understand their differences.

A full container load (FCL) fills an entire container and is a good method if you have enough goods to justify it. FCL shipments can reduce handling risks since your cargo isn’t mixed with other shippers’ goods.
A less than container load (LCL) shipment doesn’t fill a full container and is consolidated with cargo from other shippers. LCL is cost-effective for smaller shipments, but it may involve more handling, which tends to increase the risk of damage or delays.
Specialized containers may be required for unique cargo needs:
- Dry containers (the most common type) are used for general cargo such as electronics, clothing, and consumer goods. These containers are fully enclosed and protect your shipments from the elements.
- Refrigerated containers (reefers) are temperature-controlled containers and are used for perishable goods like food, pharmaceuticals, and chemicals that require consistent cooling or freezing.
- Flat rack containers have collapsible sides or no walls and are designed for oversized cargo like heavy machinery, vehicles, or large construction materials.
- Open-top containers have a removable roof, allowing for easy loading if you have tall or bulky items that can’t fit through standard container doors.

Each type of containerized load plays a crucial role in modern logistics, ensuring that your goods are transported securely and efficiently based on their unique handling and storage needs.

Benefits of containerization

Containerized shipping can improve your efficiency, security, and cost-effectiveness in several ways:

- Better use of space — Standardized containers and intelligent load planning allow for optimal packing, ensuring goods are stacked efficiently and reducing wasted space. (So you’re not paying to ship air!)
- Cost efficiency — By maximizing space and reducing manual handling, containerization will lower your transportation and labor costs. Full container loads can also help you avoid extra fees associated with less than container load consolidation.
- Enhanced security — Sealed containers protect shipments from theft, tampering, and environmental exposure. Since your goods remain enclosed from origin to destination, the risk of loss or damage due to external interference is significantly reduced.
- Improved management — Containerized shipments streamline logistics by simplifying tracking and inventory management. Standardized container sizes also make it easier for you to plan your warehouse space and transportation routes.
- Reduced damage — Containers shield your goods from weather conditions, mishandling, and external impacts. With fewer touchpoints in transit, the likelihood of damage is much lower compared to loose cargo shipments.
- Fewer errors — Automated tracking and handling systems reduce your chances of misloading, misplaced cargo, or shipping to incorrect destinations. Containerized loads improve accuracy in global supply chains.
- Environmental benefits — By improving the use of space and enabling intermodal transport (ship, rail, and truck), containerization helps you cut down on fuel consumption and emissions. A well-packed container means fewer trips, reducing your overall carbon footprint of freight transport.

The containerization process

A well-executed containerization process ensures your shipments move efficiently while maximizing space, reducing costs, and preventing damage.

1. Order preparation — Start by picking, packing, and labeling shipments based on their destination and shipping requirements. Choosing the right type of container—whether standard dry, refrigerated, or open-top—depends on your cargo’s size, weight, and handling needs.
2. Load Planning and Palletization — To make the most of your container space, you need to determine the best way to arrange your cargo. Load planning software helps you optimize cartonization and palletization, ensuring that items are packed securely, weight is distributed evenly, and available space is used efficiently.
3. Container Packing and Securing — Once your pallets are ready, they’re loaded into the container following best practices. Heavy items go on the bottom, fragile goods are cushioned, and dunnage (like airbags or bracing) prevents shifting. Proper packing reduces the risk of damage and helps your shipments arrive intact.
4. Sealing and Documentation — After packing, the container is sealed and documented for security and compliance. Accurate paperwork, including bills of lading and customs forms, helps prevent delays and ensures smooth movement through ports and checkpoints.
5. Shipping and Transit — Your container is then transported by truck, rail, or ocean freight. Real-time tracking gives you visibility into its location, estimated delivery times, and any potential delays. With proper load planning, you can minimize wasted space and shipping costs while keeping your supply chain moving efficiently.
6. Unloading and Final Delivery — Once the container arrives, it’s unloaded, and shipments are distributed to their final destinations. If needed, deconsolidation centers can break down the container’s contents into smaller shipments for last-mile delivery.

Challenges in containerized shipping

While containerization offers many benefits, it also comes with challenges that can impact your supply chain efficiency and costs.

Limited availability of containers — During peak shipping seasons or global disruptions, finding available containers can be difficult. Shortages lead to higher costs and longer wait times, making it essential to plan ahead and optimize container usage.

Regulatory and compliance considerations – Shipping across borders means navigating a complex web of customs regulations, safety standards, and environmental policies. Failure to comply with weight limits, hazardous material handling, or required documentation can lead to fines and shipment delays. Staying up to date with international regulations and using technology to automate compliance checks can help you avoid costly errors (psst, load planning software can handle that).

Even with these challenges, strategic planning and the right technology can help you navigate containerized shipping more efficiently and keep your supply chain moving smoothly.

Container freight stations (CFS)

A container freight station (CFS) is a warehouse where LCL shipments are consolidated before transport and deconsolidated upon arrival. Combining your smaller shipments with shipments from other businesses to create full container loads helps you maximize space, reduce costs, and improve efficiency in international shipping.

CFS facilities also make sure customs processing goes smoothly by providing a central location for inspections and paperwork. This will reduce your delays, lower your costs, and help keep things running smoothly.

Innovations in containerized shipping

Those who have been too busy wrangling supply chain issues to read up on containerization trends may not have noticed, but tech advancements are marching on toward efficiency, security, and cost effectiveness. Here are a few industry-shaping innovations to keep an eye on:

Automation in containerization

Automated cranes, robotic loaders, and smart sensors are transforming how containers are packed, moved, and tracked. Ports and logistics hubs increasingly rely on automation to speed up loading and unloading, reduce labor costs, and minimize human error. Have you seen these robots in the wild? Pretty sweet.

Cloud-Based Solutions for Seamless Logistics

Cloud platforms connect shippers, carriers, and logistics providers in real time, enabling better coordination and visibility across the supply chain. Integrated systems help track shipments, optimize container space, and automate compliance with international shipping regulations. Load planning software is one example of a cloud-based tool that helps businesses maximize efficiency.

Predictive Analytics in Shipping Optimization

AI-driven predictive analytics use historical and real-time data to anticipate demand, prevent bottlenecks, and optimize the use of containers. By forecasting shipping trends and potential disruptions, businesses can make smarter decisions to reduce costs and improve transit times. That’s right, AI is everywhere—and we love it!

Smart containers and IoT tracking

Have you heard of this one? Containers are now equipped with Internet of Things (IoT) sensors that provide real-time tracking, monitor temperature and humidity, and detect tampering. These smart containers help businesses reduce losses, improve security, and ensure compliance for temperature-sensitive goods like pharmaceuticals and food.

Blockchain for supply chain transparency

Blockchain technology is being used to create tamper-proof, transparent shipping records that improve documentation accuracy and reduce fraud. This is particularly useful for cross-border trade, where verifying shipment origins and tracking container movements can be complex.

Sustainable containerization

What’s next? The industry is exploring eco-friendly container materials, biofuels, and alternative energy sources to reduce carbon footprints. Some ports are even implementing fully electric cranes and automated systems to decrease emissions during container handling.

Implementing containerization with MagicLogic

Optimizing containerized shipping isn’t just about fitting goods into a box—it’s about making every inch of space count while ensuring stability, efficiency, and cost savings. MagicLogic’s advanced load planning software will help you use every inch of container space more efficiently—so you’re paying to ship your goods, not air. Whether you’re consolidating LCL shipments or planning full container loads, our intelligent algorithms ensure your cargo is packed efficiently to streamline shipping and lower your costs.

Our customizable tools are tailored to your unique shipping needs, and MagicLogic integrates seamlessly with your existing systems to automate your load planning. Your accuracy and your supply chain performance will improve. Contact us today to see how MagicLogic can transform your containerized shipping strategy.

Try MagicLogic for free!

Shipping Container Software: Optimize Your Logistics

February 18, 2025/in Container Planning, Load Planning, MagicLogic, Supply Chain/by Marilyn Bunderson

When you’re in logistics, your world never stops moving—and neither should your freight. Whether you’re managing intermodal shipments, ocean freight, or last-mile deliveries, inefficiencies in container planning and tracking can cost you time, money, and customer satisfaction. Shipping container software will help you eliminate inefficiencies and keep your operations running smoothly.

Understanding shipping container software

Shipping container software optimizes how your cargo is packed and loaded, streamlining the logistics workflow. It ensures that every container is filled efficiently, minimizing wasted space while maximizing stability. This is accomplished, in part, through integrations with warehouse management systems (WMS), transportation management systems (TMS), and enterprise resource planning (ERP) platforms to streamline the logistics process from end-to-end. Shipping container softer software can help your business cut costs, save space, and operate more efficiently.

Key benefits of shipping container software

Optimizing how your shipments are packed and processed can make a huge impact. Advanced load planning and containerization will help you eliminate inefficiencies, maximize throughput, save on shipping and transportation costs, and even improve the carbon footprint of your supply chain. Here’s a bit more information:

- Lower shipping costs: Efficient load planning means fewer containers, better use of space, and reduced dimensional weight charges—all of which lead to significant cost savings when it comes to transportation and shipping.

- Faster load planning and execution: Automated container planning eliminates manual trial and error, ensuring your shipments are optimized in seconds instead of hours. To bring this to a personal level, imagine the time and hassle you’d save if you could use load planning software next time you pack up your car for a road trip!

- Improved throughput and reduced bottlenecks: Smart cartonization, palletization, and container optimization allows your warehouses and distribution centers to move freight faster, reducing processing delays.

- Better use of space: Advanced algorithms in shipping container software ensure that every container is packed to maximize available space, reducing wasted air space and unnecessary shipments.

- Enhanced load stability and compliance: Poorly loaded containers can lead to damaged goods and rejected shipments. An advanced software solution will optimize weight distribution, stacking rules, and compliance with carrier requirements, preventing costly disruptions.

- Scalability for high-volume operations: Whether you’re shipping a few pallets or managing millions of shipments, shipping container software will automate the process at scale, ensuring efficient load planning for high-volume shippers.

- Lower environmental impact: The efficient use of space within a container ensures that you’ll use the least number of containers possible and that less void filler is necessary, both of which lower the carbon footprint of shipping your goods.

Using container software will eliminate inefficiencies and keep your freight moving as smoothly as your dog sliding into the warm spot on the couch the second you stand up.

How shipping container software works

Shipping container software streamlines load planning, ensuring that every container, pallet, and carton is packed efficiently. Here’s how the process works:

Step 1: Input your shipment data

Thanks to those integrations, shipping container software ingests your order details, including dimensions, weight, stacking constraints, and destination requirements. This will ensure that each shipment is optimized based on real-world parameters rather than guesswork.

Step 2: Let the algorithms calculate the best fit

Advanced loading algorithms determine the best way to pack your items into cartons, pallets, and containers. The system accounts for weight distribution, stability, and carrier-specific rules to prevent costly misloads or rejected shipments.

Step 3: Finalize and execute your load plan

The system generates a detailed packing plan that includes container layouts and load sequencing data to guide warehouse teams or robotics systems. This ensures faster fulfillment, optimized freight costs, and fewer delays in transit.

By automating and optimizing containerization, shipping container software eliminates inefficiencies before shipments even hit the road. The result? Fewer errors, less manual labor, and a supply chain that runs like a well-oiled machine.

The role of shipping container software in logistics optimization

Shipping container software will help your business maximize efficiency, reduce costs, and improve the overall flow of your goods through the supply chain. By automating load planning and optimizing your use of space, you’ll eliminate inefficiencies before your shipments leave the warehouse.

Plan smarter loads

Instead of relying on manual calculations, advanced algorithms determine the most efficient way to load freight into containers, pallets, or cartons, reducing wasted space and unnecessary shipments.

Fulfill orders faster

Automated load planning means your warehouse teams will spend less time figuring out how to pack shipments and more time getting orders out the door. This speeds up fulfillment and prevents costly delays.

Integrate seamlessly with your supply chain

Shipping container software that connects directly with your WMS, TMS, and ERP platforms allows your loading plans to be instantly available, and that reduces errors and keeps your logistics operations running smoothly.

Reduce your transportation costs

Optimized shipments means fewer containers, better use of space, and lower transportation costs. Your business can move more freight with fewer resources, making shipping more cost-effective.

Eliminating inefficiencies at the packing and planning stage will ensure that your freight moves through your supply chain without unnecessary slowdowns or costly mistakes.

Why shipping container software matters

Shipping container software, also known as load planning software, isn’t just about packing cargo efficiently—it’s about cutting costs, reducing waste, and improving your supply chain performance. By optimizing load planning and reducing inefficiencies, it delivers measurable benefits that impact both business operations and sustainability.

- Lower transportation costs: Every inch of wasted space in a container is money lost. Optimizing cartonization, palletization, and container loading reduces the number of shipments needed, leading to lower freight costs and fewer unnecessary surcharges. Learn more about efficient load planning with Cube-IQ.

- Environmental benefits: Reducing empty space means fewer shipments on the road, which lowers fuel consumption and emissions. Optimized loads contribute to a greener supply chain by cutting down on packaging waste and unnecessary transportation.

- Improved customer satisfaction: Faster, more efficient shipping leads to on-time deliveries, fewer damaged goods, and a more reliable experience for customers. Businesses that optimize their shipping processes can better meet delivery expectations and improve customer retention.

Eliminating inefficiencies before shipments leave the dock helps every load to be cost efficient, sustainable, and better at meeting customer expectations.

Innovations in shipping container software

The world is evolving rapidly, and that includes shipping and load planning software. Breakthrough technologies are redefining efficiency, flexibility, and decision-making. Take EasyPost Luma, for example—EasyPost’s new, unrivaled, shipping AI designed to revolutionize shipping intelligence.

From AI-powered load optimization to real-time cloud-based solutions, the next wave of innovations will reshape how you plan, pack, and ship containers. These advancements will shape the future of container optimization:

- AI in load optimization: Artificial intelligence will transform load planning by improving optimization algorithms based on real-world shipping data. Soon, AI-driven load planning tools will be able to analyze vast amounts of shipping data to predict the most efficient packing strategies, adapt in real time to disruptions, and self-optimize over time based on past performance.

- Cloud-based solutions for real-time access to load plans: As supply chains become more dynamic, real-time processing is essential. Modern shipping container software is moving to the cloud, allowing logistics teams to access optimized load plans from anywhere. This enables seamless collaboration between warehouses, carriers, and supply chain partners, ensuring that everyone works with the most up-to-date information.

- Autonomous load planning and execution: Yep, robots. Warehouse automation is evolving, and load planning software will need to integrate seamlessly with robotic palletizers, autonomous forklifts, and smart conveyor systems. Software that not only plans the optimal load but also directly communicates with robotics to execute it will significantly improve efficiency. (Psst, it’s already happening with Cube-IQ.)

- Digital twins for load planning: Have you heard of this one? A digital twin is a virtual replica of a physical system. Future load planning software may create real-time digital twins of cargo, warehouses, and transport fleets to simulate load scenarios, predict inefficiencies, and continuously refine packing strategies.

- Deeper integration with supply chain visibility tools: Load planning tools will need to become more interconnected with supply chain visibility platforms offering predictive analytics, automated adjustments, and greater interoperability with multi-carrier shipping networks. The data is there—we just need to make the right connections to use it better.

- Self-correcting load plans based on IoT and sensor data: Future load planning solutions could integrate with IoT sensors inside containers and trucks to detect shifting loads, temperature fluctuations, or cargo damage in transit—and then adjust future load plans accordingly.

Who knew the future of shipping container software could be so exciting?

Implementing shipping container software with Magic Logic

As your supply chain grows more complex, MagicLogic’s solutions will ensure that your business stays ahead with seamless system optimization, highly customizable load planning, and lightning-fast load plans. Whether you’re handling cartons, pallets, or containers, our advanced algorithms deliver precise, efficient load plans that reduce freight costs and maximize throughput.

With customizable tools designed to fit diverse shipping needs, MagicLogic will help you create load plans that align with your specific requirements. Contact us to see how MagicLogic can transform your container planning strategy, or download the software today and get started!

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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