Cut Shipping Costs With Dimensional Weight Calculations

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In shipping, every cubic inch counts. And if you’re not accounting for dimensional weight, you’re probably spending more than you should to move air.

Dimensional weight (DIM weight) is how carriers price shipments based not just on how heavy a package is, but how much space it takes up. If you’ve ever shipped a bulky item that barely moved the scale, only to be charged like it weighed a hundred pounds, you’ve seen DIM weight in action. It’s especially costly for businesses shipping high volumes of lightweight or irregular-sized goods.

If you pack a box full of helium filled balloons, the box would weigh next to nothing. But in shipping, space is money. You have to pay for the space it takes up on a pallet or in a truck. If you’re not calculating dimensional weight correctly (and early), you’re essentially paying to ship air.

Let’s break it down.

What is dimensional weight?

Man measuring a large parcel

Dimensional weight is a pricing method used by shipping carriers to reflect the amount of space a package occupies in relation to its actual w

eight. Instead of charging solely by the number on the scale, carriers charge based on whichever is greater: the actual weight or the dimensional weight. 

This matters most when you’re shipping large, lightweight items like pillows, plastic containers, or, yes, a box of packing peanuts. A package might weigh only five pounds, but if it takes up the same space as a 20-pound box, the carrier will likely bill you for 20 pounds. 

In short: 

  • Actual weight is what the package physically weighs. 
  • Dimensional weight is what the package is priced as based on its size. 

 

How to calculate dimensional weight

Don’t get caught off guard by your shipping charges! You can calculate DIM weight as follows: 

1. Measure your package

The length, width, and height of the package is used in calculating the dimensional weight. Sadly, you can’t rely on the dimensions printed on the box because they may not be accurate once the box is packed. 

2. Round each measurement

Carriers require that you round each dimension to the nearest whole inch. So for example, if the measurement is 10.5 inches, you would round up to 11 inches. If it’s less than 10.5 inches, you can round down to 10. Always round each dimension separately. 

3. Calculate volume

To find the volume, multiply the rounded length x width x height. This will give you the cubic volume in inches. A box measuring 30 x 12 x 12 would be 4,320 cubic inches. 

4. Divide by the DIM factor

Now, divide the volume by the carrier’s DIM divisor. The default for most domestic shipments (UPS, FedEx, USPS) is 166. For international shipments, the carrier default is 139. 

Using the example above, 4,320 divided by 166 is 26 pounds for a domestic shipment. 

5. Compare to actual weight

Next weight the package on a scale. Whichever number is higher—the actual or dimensional weight—is the number you’ll be billed for. 

With our example above, if the actual weight is 12 pounds, you’ll get charged for a DIM weight of 26 pounds. If the actual weight is 30 pounds, you’ll get charged for 30 pounds. 

Plan smarter, ship for lest

Account for dimensional weight with Cube-IQ

Most shippers slip up here: they calculate dimensional weight after packing the box. Why is this a problem? When the freight is ready to go, and the carrier is selected, the cost is locked in. Just like that, they’ve missed out on cost-saving opportunities. 

You wouldn’t wait to figure out how much legroom you need until after boarding the plane, would you? If you need more legroom, you buy a seat with more space for your long legs. Once you’re on the plane it’s too hard to adjust.  

Cube-IQ takes a smarter approach. It calculates dimensional weight during load planning, so your team can optimize before a single box is packed. Whether you’re working with small parcels or large pallets, Cube-IQ helps you choose the best configuration, factoring in dimensional weight in real time. 

Let’s go back to that 12 pound package. You don’t want to pay for 26 pounds if you can help it. If the product can fit into a 12 x 12 x 12 box, the dimensional weight for that would be 10 pounds. You would be charged to ship 12 pounds—the actual weight. 

Need to work in inches and pounds one day and centimeters and kilos the next? Cube-IQ supports mixed units, meaning it is ideal for global shipping teams that need flexibility and precision. 

Best of all, Cube-IQ simulates multiple packing options so you can compare outcomes and choose the most cost-effective strategy before anyone picks up a tape gun. 

Learn more about Cube-IQ. 

Common mistakes and how to avoid them

1. Incorrect box size

Why it’s a problem: Oversized boxes are DIM weight traps. You might think you’re protecting the product, but you’re really just inflating shipping costs. 

How to avoid it: Use right-sized boxes that fit your product snugly. Reduce unnecessary void space and consider custom packaging if your inventory has consistent dimensions. 

2. Neglecting packaging weight

Why it’s a problem: Packing materials like bubble wrap, tape, and foam add weight that is often overlooked. That leads to unexpected costs and underbilled shipments. 

How to avoid it: Weigh the fully packed box, not just the product. In addition, keep track of packaging weight separately to improve your shipping estimates and margin forecasts. 

3. Inaccurate measurements

Why it’s a problem: Measurement errors, especially rounding down, can lead to billing disputes or surprise fees when the carrier re-measures. 

How to avoid it: Always measure from the longest points. Round up, use consistent measuring tools, and consider automating measurements with scanning systems if they are available to you. 

4. Dimensional weight vs. actual weight

Why it’s a problem: If your shipping team is focusing only on actual weight, it could be a problem. In many cases, DIM weight is higher, and the carrier will choose the higher option. 

How to avoid it: Calculate both and bill your customers (or build pricing models) accordingly. Tools like Cube-IQ automate this process so you’re not stuck doing manual comparisons. 

5. Minimizing void space

Why it’s a problem: Extra space in a box equals extra cost. ANd with dimensional weight, it doesn’t take much air to drive up the price. 

How to avoid it: Optimize void fill and packaging selection. For multi-item orders, use cartonization software to maximize your use of space and reduce dimensional charges. 

Explore smarter palletization strategies.  

Account for dimensional weight with Cube-IQ

Most businesses calculate dimensional weight after the fact—once the items are packed, taped up, and ready to ship. By then, it’s too late to optimize. Manual estimates or static calculators miss cost-saving opportunities because they react instead of plan.

Cube-IQ flips the script. It accounts for dimensional weight during load planning before a single box is packed. That way, you can make strategic decisions from the start. It updates in real time as your configurations change and supports mixed units for international teams juggling inches and centimeters, pounds and kilos.

The result? Smarter packing and real savings. Cube-IQ simulates different packing options to help you choose the most efficient one, whether you’re trying to minimize box size, avoid airspace, or reduce freight charges. It’s proactive, precise, and built to cut costs before they stack up.

Common mistakes and how to avoid them

Even small missteps in how you pack and measure can lead to big shipping costs. From choosing the wrong box to forgetting the weight of the bubble wrap, you should make every effort to avoid these five common dimensional weight mistakes. 

1. Incorrect box size

Using a box that’s too big for your product may seem harmless, but oversized boxes inflate dimensional weight and increase shipping costs. 

Avoid it: Choose boxes that closely match the size of your product. Cut down on excess space and consider custom-sized packaging if your items are consistent in shape and size. 

2. Neglecting packaging weight

Packing materials add more weight than you think. Bubble wrap, foam inserts, air pillows, tape—it all adds up. And if you’re not accounting for it, you could end up drastically underestimating shipping costs or undercharging your customers. 

Avoid it: Weigh the entire package after it’s packed,  not just the product inside. Keep a running tally of common packaging material and their weights to improve future estimates and margin accuracy.  

3. Inaccurate measurements

When it comes to DIM weight, an inch can make a big difference. Rounding down or skipping the re-measure after packing can lead to billing discrepancies, unexpected charges, or even reclassification from many carriers. 

Avoid it: Measure from the longest points on each side of the box and always round up to the nearest whole inch. Use the same measuring tools across your operation for consistency and accuracy. 

4. Dimensional weight vs. actual weight

It’s easy to focus on the number the scale gives you, but that’s only half the equation. Many shipping teams overlook dimensional weight entirely and end up surprised by higher charges when the carrier defaults to the larger number.

Avoid it: Calculate both the actual weight and the dimensional weight every time. Bill based on whichever is higher, or use a solution like Cube-IQ to automate this step and ensure your rates are accurate from the start.

5. Minimizing void space

Void space is the silent cost driver in shipping. The more air in your box, the more you’re charged. And it doesn’t take much extra room to tip the scales against you.

Avoid it: Use void fill to stabilize items, but don’t overdo it. Select packaging that fits the contents snugly, and for multi-item orders, consider mixed palletization strategies to make the most of your space. Explore smarter palletization strategies. 

Smarter Packing Starts Here

Dimensional weight charges may seem like just another shipping fee, but when ignored, they quietly inflate your costs. The good news? They’re also one of the easiest areas to control if you plan ahead.

Cube-IQ helps you stop shipping air and start shipping smarter. With real-time optimization, flexible unit support, and automated comparisons, your team can right-size packaging, minimize void space, and keep dimensional charges in check.

Ready to turn your packing peanuts into profit? Get started with Cube-IQ today. 

partially loaded containerized load

What Is a Containerized Load? Types, Benefits and Challenges

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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. 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. 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. 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. 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. 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. 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

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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! 

cartons on a conveyor belt in a warehouse

What Is Cartonization? Tools and Techniques

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A leading subscription box company, FabFitFun, was having some cartonization issues. They send quarterly boxes of products to their subscribers. When they started offering their customers the ability to customize the boxes, cartonization became more complicated. They turned to MagicLogic to solve the problem, and they ended up saving millions of dollars each quarter. 

Understanding cartonization

Why would cartonization optimization help a company save millions of dollars? Great question. Cartonization is the process of placing products into a box (or carton), but it’s not just about finding any box that fits. Optimized cartonization means you use the right-sized box for the products with minimal wasted space and a reduced need for filler material.

Have you ever received an online order with a very small product in a box ten times too big? That’s overboxing. To simplify a complex issue, using bigger boxes than needed will cost more money in shipping charges. Obviously there’s more to it. Keep reading. 

Types of cartonization

Let’s start by understanding various types of cartonization relevant to logistics. Each type offers unique benefits depending on the complexity of your product offerings, the volume of your orders, and the level of optimization within your fulfillment process. Knowing which type of cartonization is right for your business will improve efficiency and reduce costs. 

    • Manual cartonization: Exactly as it sounds, manual cartonization means workers manually select the appropriate box size based on their experience or predetermined guidelines. It’s more labor-intensive than other methods and can lead to wasted space, wrong box sizes, and wasted time.  
    • Fixed-size cartonization: A step above manual cartonization, fixed-size cartonization means a specific set of box sizes is used, and products are automatically assigned to the closest matching size. This can be faster than the fully manual process, but it may not result in the most efficient solution, as variations in product dimensions and packing needs are not fully accounted for. 
    • Dynamic cartonization: With dynamic cartonization, algorithms and data are used to automatically select the most optimal box size based on product dimensions and packing requirements. This method ensures the best use of space while reducing material costs and improving shipping efficiency. 
    • Multi-product cartonization: If you need to pack multiple items in a box, that’s multi-product cartonization. For this method, the size and shape of each item must be taken into account to determine how to arrange the products into the box for the most efficient use of space. As FabFitFun found, this can be complicated.  
    • Robotic cartonization: This advanced form of cartonization puts robots to work to automatically select and pack items into cartons. Robotics can significantly speed the process, improve accuracy, and be more efficient, especially in high-volume warehouses and fulfillment centers. 
    • Layered cartonization: This method is particularly good for oddly shaped or delicate items that need to be packed with extra care. Placing the products in layers can improve stability and keep the products safe during shipping.  

 

The cartonization process

The cartonization process can be broken down into the following steps: 

1. Assess your products

Start by taking a good look at your products. Are they large and boxy, small and fragile, or somewhere in between? Understanding the size, shape, and nature of each item is key to figuring out the best way to pack it. 

2. Select the optimal box size

Once you know exactly what you’re packing, it’s time to channel your inner Goldilocks and find the perfect box. Not too big, not too small. Your goal is to fill the space with products to minimize wasted space but make sure it all fits snugly to keep things safe. Also keep in mind that smaller boxes can be less expensive to ship, so the optimal box size can save you money. 

3. Arrange the products in the box

Are you a Tetris aficionado? If so, this is your moment to shine! The key here is to arrange your products in a way that maximizes space and keeps everything secure. That generally means put heavier things on the bottom with fragile items on top, and use filler to keep things secure. 

4. Fill the empty space with padding

You’ll probably have a bit of extra space left, and that means it’s time to add a bit of filler so things don’t shift around too much. You can use anything from crumpled paper to bubble wrap, foam peanuts to air pillows. For especially fragile items, molded pulp is a great option, especially if you want to be environmentally friendly. 

5. Finalize for shipment

Whew, you’re almost there! Next, seal up the box with tape, slap on a shipping label, and give it a quick once-over to make sure everything’s good to go. Now it’s ready for delivery, whether it’s across town or on the other side of the world. 

The role of warehouse management systems in cartonization

When it comes to automating your cartonization, your Warehouse Management System (WMS) isn’t just a bystander—it’s the behind-the-scenes wizard making sure everything runs smoothly. Your WMS plays a starring role when combined with cartonization software:

    • Integrating cartonization software with your WMS: Think of your WMS as the mastermind orchestrating the perfect packing process. By integrating cartonization software directly into your WMS, the cartonization system can automatically select the right box for each product. No more guesswork or last-minute decisions. It’s like having a packing pro on hand 24/7!
    • Real-time data synchronization
      Imagine trying to pack a box without knowing what’s in it—chaos, right? WMS ensures real-time synchronization of all inventory and order data. This means cartonization decisions made by your cartonization software are based on the most up-to-date information, making sure you never over-pack (or under-pack) and always use the most efficient box size for each order.
    • Operational efficiency with WMS When it’s paired with cartonization software, your WMS does more than keeping track of your inventory. It boosts your operational efficiency by automating the carton selection and arrangement process, speeding up packing times, reducing human error, and maximizing warehouse space. The result? More efficient operations with fewer boxes wasted (and everyone’s happier). 

Why cartonization matters

Automating your cartonization is a game-changer for your entire logistics process. Why? It will lower your shipping costs and improve packing efficiency, sustainability, and customer satisfaction. Bold claims, you say? Let me explain:

Lower shipping costs

When it comes to shipping, size matters—literally. When you optimize your cartonization, you’re using the smallest box that fits the product while keeping it secure, and that reduces excess weight and volume (especially if your carrier uses dimensional weight to calculate rates). That reduces shipping costs because you’re not paying to ship empty space. It’s like getting a discount for packing smarter. 

Improved packaging efficiency

Warehouse workers who have to do all the thinking for themselves take valuable time to choose the right size box, try to fit the products in it, and add in the proper amount of packing material. Let’s do some simple math: A warehouse worker may pack 150 packages an hour, which translates to 24 seconds spent on each. If it takes two to four seconds for them to make these decisions, automated cartonization software will save each worker five to ten minutes in an hour. Out of an eight-hour work day, that’s over an hour of their time. Multiply that by 10 warehouse workers, and it starts to add up—especially when you consider that warehouse worker pay has increased by 48% in the last seven years. 

More eco friendly

Optimizing your cartonization will save you more than just money—you’ll also be saving the planet. Using the right-sized box means you’ll cut down on fillers, reducing material waste and reducing your environmental footprint. FabFitFun, the company mentioned at the beginning of this article, reduced their carton packing material by 30% to 35% when they started using cartonization software. It’s packing with a purpose, and it’s good for business (and the Earth). 

Increased customer satisfaction

At the end of the day, customers care about two things: the condition of their products and the speed at which they arrive. Efficient cartonization ensures their products arrive safe and sound, with no unnecessary waste. Customers appreciate receiving their orders in a perfectly packed box with no damage, no excess, and have a great unboxing experience. (Note: Unboxing videos are still going strong. If your brand shows up in an unboxing video, make sure it’s a good experience.)

Innovations in Cartonization

Like everything else in logistics, cartonization is changing rapidly. It’s not just about using the right box, it’s about using the smartest tools available. Watch for these innovations that will change the way we box up our shipments in the coming months and years: 

Advanced robotics

Robotic systems are already making waves in warehouses, and the next frontier will include more intelligent and autonomous robots that can not only pack products but also assess product characteristics in real time. The robots will be adaptable to work with fragile goods to irregularly shaped products and more, with minimal human intervention. This will improve packing speeds, reduce labor costs, and improve accuracy in packing. 

Cloud-based solutions 

The cloud makes cartonization easier and more accessible than ever. A cloud-based cartonization solution allows you to access the needed tools from anywhere, at any time, with no hassle. Whether you’re working from a tablet on the warehouse floor or tracking metrics from the comfort of your office, cloud technology connects it all for smoother, more efficient operations. 

3D scanning and visualization

Warehouses will soon be able to use 3D scanning technology to create digital models of each product, providing precise measurements for cartonization. This will help determine optimal packing methods based on shape and size down to the millimeter. 

Sustainable packing solutions

As the world moves toward sustainability, we will see a greater need for biodegradable and recyclable packing materials. Innovations in compostable packing peanuts, paper-based air pillows, and molded pulp will figure more prominently, and plant-based plastics may become more mainstream. This will produce less waste and a lower carbon footprint for those who embrace these innovations. 

Predictive analytics

Predictive analytics looks at historical data and trends and forecasts future packing needs, helping you anticipate demand and optimizing packing strategies. It’s like having a crystal ball for your warehouse, ensuring you’re always one step ahead in managing packaging and shipping processes. 

Implementing Cartonization With MagicLogic

Want help automating your cartonization? MagicLogic’s Cube-IQ is the most powerful and advanced solution on the market. Here’s why: 

    • Unrivaled speed: Our carton selection response speed is under 100 milliseconds, allowing you to process 100 orders per second with real-time shipment evaluations before the customer clicks. 
    • Customizable solution: Our solution is fully customizable to fit your unique needs, providing the flexibility to adapt to even the most complex requirements. 
    • High-quality coding: Our industry-leading coding ensures top-tier performance and seamless operation. 
    • Adaptive handling of unique-shaped parcels: You can tailor your packing strategies for parcels of all shapes and sizes. 
    • Seamless integration: MagicLogic integrates easily with your existing WM, ERP, and other systems for a smooth transition and continuity in your operations. 
    • Graphical user interface (GUI): Our comprehensive user interface has drag-and-drop functionality with 3D graphics for creating loading jobs.
    • Trusted by the biggest brands: Leading brands like Honeywell, Starbucks, Nestle, P&G, Johnson&Jonson, and The Home Depot use MagicLogic. 
    • 24 years in the industry: We’ve demonstrated enduring reliability and continuous innovation in load planning. 

 

Oh, and one more thing, you can take it for a test drive for free. In fact, many MagicLogic users started with a free trial and found that the savings and efficiency gains easily justified the investment. Optimize your cartonization and start saving today!

Containers on a barge

Container Planning Guide: Maximize Space and Efficiency

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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? 

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. 

 

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. 

Container planning in three steps

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) 

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.

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.

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?

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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! 

MagicLogic Optimization Inc. Selected as 2023 Top 100 Logistics IT Provider – Our 21st Consecutive Year Receiving This Award

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We are proud to announce that once again, Inbound Logistics has selected MagicLogic Optimization as a Top 100 Logistics Provider for 2023. We have now been selected for this award for 21 consecutive years. It is always an honour to receive this award, and we like to display our Top 100 badge on our website and communications with customers.
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“Every April for the past 25 years, Inbound Logistics editors have selected 100 logistics technology companies that enable logistics and supply chain excellence’ explains Inbound Logistics editor Felecia Stratton. “MagicLogic Optimization Inc. was recognized for leading the way in 2023 and positioning enterprises to scale and grow. MagicLogic Optimization Inc. excels at providing solutions that drive supply chain excellence and answer IL readers’ needs for simplicity, ROI, and frictionless implementation. Inbound Logistics is proud to honor MagicLogic Optimization Inc. for continuing to offer our readers solutions that optimize logistics and supply chain excellence and drive enterprise performance.”

MagicLogic is constantly working on improving our load optimization software further and building and strengthening industry partnerships. Our recent introduction of Cube-IQ Web and hosted BlackBox solutions are proving extremely popular, with companies increasingly seeking more mobile solutions suited to today’s workforce.

R&D of existing and new products is incredibly important to us, so we can continue to cater to the changing needs of our customers. Felecia elaborates further on how our company was selected: “Top 100 Logistics IT Providers such as MagicLogic Optimization Inc. help customers navigate the complexities of global trade and expansion. MagicLogic Optimization Inc. provides the technology solutions Inbound Logistics readers need to successfully manage their global enterprises, minimize disruption damage, and adapt to changing trade currents. Accordingly, Inbound Logistics is proud to honor MagicLogic Optimization’s innovative solutions empowering global logistics and supply chain excellence.”

The Selection Process

Every April, Inbound Logistics editors recognize 100 logistics IT companies that support and enable enterprise excellence. Drawn from a pool of more than 300 companies, using questionnaires, phone calls, personal interviews, and other research, Inbound Logistics selects the Top 100 Logistics IT Providers who are leading the way to efficiency for 2023 and beyond. Editors match our readers’ fast-changing needs to the capabilities of those companies selected.  All companies selected reflect leadership by answering and anticipating supply chain leaders’ needs for simplicity, flexible pricing, ROI, and frictionless implementation.

About Inbound Logistics

Inbound Logistics is the pioneering magazine empowering demand-driven enterprises. IL’s educational mission is to guide businesses to efficiently manage logistics, reduce and speed inventory, and neutralize transportation cost increases by aligning supply to demand and adjusting enterprise functions to support that paradigm shift. More information about demand-driven enterprise practices is available at www.inboundlogistics.com

About Our Load Optimization Software

MagicLogic load optimization solutions are suitable for small to medium-sized companies and larger multinationals shipping thousands of products daily. Our Cube-IQ Load Optimization software includes our subscription-based service, where users can access the software from their smartphone, tablet or browser, and is perfect for flexible workplaces. BlackBox, our flagship product, can handle complex Cartonization and palletization, including true robotic palletization. BlackBox integrates easily with any WMS/ERP system, including legacy systems. Industry-specific solutions tailored to accommodate specific requirements are available. We also offer a custom service for companies with unique shipping requirements.
Please contact us to learn more about our software solutions and to arrange a quick demo.

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Organize Your Shipping Systems With Palletization Software

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Palletization software is a vital part of supply chain operations and is designed to help with the process of placing items to be shipped onto pallets. The software automates what has historically been a manual and time-consuming task, ensuring that goods are arranged efficiently and securely on pallets to maximize space, reduce the risk of damage, and improve overall handling.

What is palletization

Palletization is the process of stacking goods or materials onto a pallet, a flat structure designed to support and stabilize them during storage and transportation. The main purpose of pallet building software is to organize the handling, storage, and movement of goods, making them easier to transport by forklifts, trucks, and other machinery. When pallets were originally introduced, the impact on material handling was dramatic.

Benefits of palletization

Faster delivery

Using pallets as a base for goods allows them to be loaded and unloaded far more quickly and efficiently, saving hours of human resources, reducing labor costs, and enabling a faster turnaround and transportation of products.

More efficient handling

Operators can insert and remove pallets more effectively, as handling equipment can stack products, reducing the number of movements required.

Lower labor costs

Labor requirements are reduced dramatically with palletization. Moving fully loaded pallets allows warehouse workers to move a greater volume of goods during each shift.

Protection of perishable goods

Palletization is particularly important for perishable goods that must be kept refrigerated. Using pallets allows these goods to be moved more quickly across unrefrigerated areas, and they can be loaded and unloaded more quickly.

Lower risk of damaged goods and freight loss

Proper palletization reduces damage to goods, protecting items and ensuring that products remain in perfect condition until the pallet is unloaded and ready for the next part of the supply chain. Items secured on pallets are bound together with plastic wrap, strapping, or both, so the chance of items falling off are low.

Warehouse staff safety

When items are palletized correctly, the pallet is stable, reducing the chance of injury to workers.

Warehouse storage optimization

Material handling is more efficient, enabling better optimization of warehouse storage, since one key factor in optimizing transportation is stackability.

Better inventory control

Palletizing loads enables better inventory control, as it is easier to monitor each SKU. Logistics managers can gauge a product’s stock level at a glance since they will know the number of products stored on each pallet.

Versatility

Usually, goods loaded onto pallets are stacked on top of one another in columns, resting directly on the item below. However, load strength and stability considerably increase when pallets are loaded in an interlocking pattern. Achieving the best loading pattern is not easy. Additionally, some goods are not suitable for palletization. These include long and thin items or irregularly shaped items that will not stack easily.

Choosing the best way to palletize

pallet loading

You can choose from a variety of palletization methods, as long as you keep stability in mind. The following tips will improve your palletization process:

  • Use cartons or boxes: Opt for regular-shaped cartons or boxes to ensure goods can be neatly stacked, resulting in more even loading.
  • Fill to max capacity: Pack the boxes as full as possible within weight and size limits.
  • Ensure even stacking: Avoid uneven stacking or bulging loads to maintain stability, and be sure to distribute items on the pallet evenly by weight.
  • Create a compact structure: Aim for a compact and uniform load structure for enhanced stability, without any items extending past the pallet base.
  • Wrap the load with transparent film: Secure the load by wrapping it in transparent film to protect the goods and keep them together.
  • Use strapping for additional  security: Consider using strapping to further secure the load and bind the goods together.

Consider pallet characteristics

Pallets are available in several standard sizes, helping optimize supply chain operations. A standard pallet is 40 x 48 x 5 inches, and most shipping companies base their freight charges on pallet volume. Using pallets can add 20% – 30% volume to a shipment, so proper optimization is essential to ensure the pallets achieve maximum volume. Most companies use standard-sized boxes that are easier to stack without wasting space, but this isn’t possible for every order.

Pallets can be made from different materials, depending on the goods to be shipped. These include pallets made from wood, metal, or plastic. Pallets can also be selected according to the storage systems available in the warehouse, the handling equipment that can be manual or automatic, and facilities available at supplier locations.

Using blackbox logistics pallet loading software

MagicLogic BlackBox software includes a separate optimization engine developed specifically for palletization, including complex mixed-case pallet stacking. Our palletizing software can build layers and semi-layers. It can also automatically switch to free stacking when required. The main aim of our palletization engine is to achieve excellent pallet stability, maximum fill quality, and maximum load stability. It supports manual pack stations and robotics.

These days, more companies are choosing to automate or semi-automate their logistics operations, and BlackBox can provide packing sequences suitable for robotics. Robotics is especially useful for packaging pharmaceutical goods and the food industry, ensuring goods remain clean and hygienic during palletization.

Our BlackBox palletization software includes configurable parameters for different end-of-arm tools and approach points, allowing users to achieve true mixed case robotized palletization. Our R&D team spent considerable time solving this difficult problem effectively and is rightly proud of this achievement.

Easy to integrate with your WMS/TMS

We designed our BlackBox to be configured to work with any system that generates data to a standard schema, using powerful APIs that ensure system integrators will be up and running within a few days.

Custom solutions available

Over half of our business focuses on providing custom solutions to meet customers’ specific requirements. Many of our customers need to ship products that must be packed in a certain way to ensure they arrive in perfect condition and are accepted by the end-user. We specialize in finding solutions for tricky problems using our decades of experience and knowledge gained within the supply chain industry. For more information you can reach out to our customer success team.

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20 Years in the Top 100

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MagicLogic Optimization Inc. Selected as 2022 Top 100 Logistics IT Provider – Our 20th Consecutive Year Receiving This Award

We were recently thrilled to learn that MagicLogic Optimization has yet again been selected as an Inbound Logistics Top 100 Logistics IT Provider for 2022. This marks our 20th consecutive year receiving this honor. We never take this award for granted and are always proud to display the latest Top 100 badge on our website and in all communications with customers.

Inbound Logistics editors recognize 100 logistics IT companies that support and enable logistics excellence. Drawn from a pool of more than 300 companies, using questionnaires, phone calls, personal interviews, and other research, Inbound Logistics selects the Top 100 Logistics IT Providers who are leading the way to efficiency for 2023. Editors seek to match readers’ fast-changing needs to the capabilities of those companies selected.  All companies selected reflect leadership by answering Inbound Logistics readers’ needs for simplicity, flexible pricing, ROI, and frictionless implementation.

Felecia Stratton, Inbound Logistics Editor, explains: “Every April for the past 24 years, Inbound Logistics editors have selected 100 logistics technology companies that enable logistics and supply chain excellence. MagicLogic Optimization was recognized by Inbound Logistics for leading the way in 2022 and positioning enterprises for the years ahead. MagicLogic excels at providing solutions that drive supply chain excellence and answer IL readers’ need for simplicity, ROI, and frictionless implementation. Inbound Logistics is proud to honor MagicLogic for continuing to offer our readers solutions that optimize logistics and supply chain excellence.”

Supply chains worldwide have continued to be under unprecedented pressure over the past two years. These are compounded further by rising fuel costs and the rising prices of essential commodities, coupled with continuing labor shortages and with no end in sight. MagicLogic provides a suite of software solutions to ensure products are loaded more efficiently and safely, so they can arrive in pristine condition. Our innovative software solutions are designed to be intuitive, and even an inexperienced user will be up and running within just an hour or so with our tuition.

Felecia Stratton elaborates further on how they selected MagicLogic. “Implementing the best logistics technology helps large companies expand markets and drive undiscovered efficiencies. World-class solutions such as MagicLogic Optimization are force equalizers for SMEs by leveling the playing field with their larger competitors. Best-in-class logistics IT also helps today’s business logistics managers boost supply chain performance and customer service while cutting overall logistics costs. Inbound Logistics editors selected MagicLogic for its consistent ability to deliver innovative solutions empowering logistics and supply chain excellence for companies large and small.”

About Inbound Logistics

Inbound Logistics is the pioneering magazine empowering demand-driven enterprises. IL’s educational mission is to guide businesses to efficiently manage logistics, reduce and speed inventory, and neutralize transportation cost increases by aligning supply to demand and adjusting enterprise functions to support that paradigm shift. More information about demand-driven logistics practices is available at www.inboundlogistics.com

About Our Load Optimization Software

MagicLogic provides load optimization solutions for all sized companies, including those who might only load a few containers a month, right up to multinationals shipping thousands of orders each day.

Our products include Cube-IQ Load Optimization software and Cube-IQ Web, our subscription service allowing users to access our software from their tablet, browser, or smartphone no matter where they are. As workplace flexibility looks set to stay, our web version is becoming increasingly popular.

BlackBox is our flagship product, handling complex Cartonization and palletization with ease, including true robot palletization. BlackBox integrates seamlessly with any WMS/ERP system and can be up and running within a short while. We also offer industry-specific solutions tailored to accommodate unique requirements or can customize our software to suit the needs of the client. Contact us to learn more about our software solutions.

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MagicLogic Optimization Inc. Selected as 2021 Top 100 Logistics IT Provider

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We are delighted to announce the editorial team at Inbound Logistics has selected MagicLogic Optimization Inc. as a Top 100 Logistics IT Provider for 2021. This marks the nineteenth consecutive year MagicLogic has been chosen for this honor. Each year, we proudly display our Top 100 badge on communications with customers and on our website.

Every April, Inbound Logistics selects the Top 100 Logistics IT Providers who are leading the way in 2021. The editors make their selection using research, questionnaires, and personal interviews from a pool of more than 400 companies.

Felecia Stratton, Editor of Inbound Logistics, elaborates on how they choose the Top 100: “When choosing the 2021 Top 100 Logistics IT Providers, Inbound Logistics editors looked at excellence in optimizing supply chain, logistics, and transportation operations. Strategically, editors make their selections based on how transformative solutions impact those business activities driving integration across internal and external business processes. MagicLogic Optimization Inc. was selected because its solutions solve specific logistics challenges and improve processes, and create a ripple effect of enterprise efficiencies across the entire value chain.”

The past year has tested the strength of supply chains like never before. MagicLogic has risen to the challenge. Our team continues to solve complex logistical problems and customize our software solutions to meet the current demands and are an important part of the supply chain for many top-tier companies.

Felecia Stratton explains further how these problems have affected companies: ”The business disruptions of the past year remind businesses to focus like a laser beam on improving enterprise operations through investments in technology. The challenges are many and are now top of mind. Improving end-to-end visibility, achieving closer integration with value chain partners, finding efficient sources of transport lift, nailing down chain of custody and sustainability concerns to limit liability, inventory scalability have clearly become survival issues for many. MagicLogic was selected as a Top 100 Logistics IT Provider because its solutions address these critical needs and help companies move along the continuum to truly becoming demand driven enterprises.”

MagicLogic provides loading software designed to grow with companies, loading more and ensuring orders arrive in pristine condition. It is increasingly likely that the challenges presented by COVID-19 will change consumers’ shopping habits for good. While B2B growth remains strong, there is a continuing need for B2C solutions. Our flagship product, BlackBoxTM, integrates seamlessly with any WMS/EMS system and handles Cartonization and palletization, and ensures the correct cartons are selected for online orders in near real-time, minimizing fill material and reducing shipping costs.

About Inbound Logistics

Since its inception in 1981, Inbound Logistics’ educational mission is to illustrate the benefits of demand-driven logistics practices, give companies the knowledge to help them match the inbound flow of materials to their demand, and align their business process to support that shift. Inbound Logistics offers real-world examples and decision support to guide businesses to efficiently manage logistics, reduce and speed inventory, offset rising transport costs, and balance transport needs with demand, supporting business scalability across their value chain. More information about demand-driven logistics practices is available at www.inboundlogistics.com

Contact

Suite 170, 422 Richards St.Vancouver, BC Canada V6B 2Z4
+1 206 274 6248 (PST)
info@magiclogic.com

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