When you pack an item for shipping, the mere thought of it breaking into pieces is unsettling. The thing is, any item can be potentially damaged, may it be a fragile vase or even a simple book. That is why packing everything correctly is the first crucial step before shipping a cargo. To do so, you will need pallets and boxes.

Boxes need no explanation, but what are pallets? Pallets are lightweight platforms for moving, storing, and transporting goods. A pallet offers a stable foundation for stacking several products, and it is designed to be portable using either a pallet jack or forklift. So, what is the best way to pack pallets and boxes? Let’s walk through a few simple steps to ensure that your cargo arrives safe and sound.

Choose the Right Pallet

Choose the Right Pallet

Before you even start packing, you need to pick the right pallet. Not all of them are made equal. They vary in material (wood, plastic, metal), size, and construction. The choice of pallet often depends on the product's weight, dimensions, and shipping requirements. For instance, perishable goods might require plastic pallets for better hygiene, while heavy machinery might be best suited for sturdy wooden pallets.

What to Consider When Choosing a Pallet?

What to Consider When Choosing a Pallet?

Pallets are not a complicated mathematical equation. However, there are a few factors you might need to consider when choosing one.

Durability: Goods in pallets are often transported piled on top of each other and exposed to environmental changes. To prevent the goods from being damaged by forklift blades, use a sturdy pallet with a sufficient topboard gap.

Strength: This factor usually depends on the materials used for pallets. Make sure to pick the one with a strong foundation that can carry your goods.

Price: Try to find the balance between the pallet's price and quality. Understandably, preference should be given to quality, but there are plenty of affordable options that do not compromise on quality.

How to Properly Pack Your Box?

How to Properly Pack Your Box?

Pallets are the base of the cargo. Now onto the box packing. Please consider these important steps when you pack your cargo.

Use Filler to Avoid the Ruttle

Shaking boxes are not fun, especially during transportation. Any space left should be filled with materials like crumpled newspapers, packing peanuts, or air pillows. This ensures your item stays put, minimising damage.

Bubble Wrap Protection

Bubble wrap is a must-have layer of protection when it comes to fragile items. The best way to pack a box would be to place a layer of bubble wrap at the bottom of it and then wrap each item individually. Since it’s a flexible material, you can wrap your goods a few times. Technically, the more fragile the item is, the more bubble wrap you’ll want.

Bubble Wrap Alternative - Soft Foam

Both bubble wrap and soft foam are great materials that protect the items during shipping. Cut-to-size foam sheets are most often used as cushioning when transporting electronics, delicate goods, or things with sharp edges or components. While useful in these particular situations, foam sheets are typically worthless when the packing boxes are too big.

Seal It Tight

Once the box is properly packed, you will need to seal it. Use strong packing tape, and make sure to tape all flaps, even those on the bottom of the box. Sometimes, it’s good to roll the tape around the box 2 or 3 times, ensuring everything is tightly sealed.

Label Clearly, Especially for International Shipments

Labelling is one of the last and most important steps in packing cargo. Make sure to include the destination and return address. Clear labelling of the box is essential, especially if you’re shipping internationally. Please keep in mind that international shipments may also require additional customs documentation.

Consider Insurance

Having insurance is always a good idea, but if you’re shipping an item of high value, consider purchasing additional insurance. If something goes wrong, you’ll have nothing to worry about. The extra peace of mind is definitely worth it.

How to Secure Your Pallet

How to Secure Your Pallet

Now to the most crucial part. Let’s go over a few important steps of preparing your pallet for shipping.

The Layers of Packaging

Base Layer: The primary layer directly sits on the pallet. It often consists of heavier items that serve as a solid foundation. It's essential to ensure this layer is evenly distributed to prevent any tilting or imbalance during transit.

Intermediate Layer: This can be composed of a mix of products. When placing items, it's important to consider their shape and weight, ensuring that the overall structure remains stable. Spaces between boxes or products can be filled with cushioning material, preventing movement.

Top Layer: Ideally, this layer comprises lighter items. It's also where any fragile items should be placed, given that they're adequately protected. This layer can also be shielded with a corrugated sheet or another protective layer to prevent damage from external elements.

Pallet Caps and Corners

Pallet Caps and Corners

To provide additional protection, pallet caps (sheets of card or plastic) can be placed over the top layer. This prevents damage from any items that might be placed on top of the pallet during transportation. Additionally, protective corners can be added to prevent abrasion or damage to the edges of the packages.

Wrapping and Securing the Load

Wrapping and Securing the Load

Once products are systematically stacked on the pallet, the next step is to secure the load. This is typically done using stretch wrap, a plastic film that adheres to itself. The wrapping process begins from the base and continues upwards in a spiral manner. This technique provides several benefits:

Stability: It tightly binds the products, ensuring they remain stationary during transit.

Protection: It acts as a shield against dust, moisture, and other environmental elements.

Tamper-Evidence: Any meddling or tampering becomes evident, adding a layer of security to the shipment.

You can also use bands made of materials like polyester or polypropylene to ensure the pallet's stability.

Pallet Loading Methods

Pallet Loading Methods

Generally, there are several ways of loading the pallet. However, we would recommend either column or interlocking stack.

Interlocking Stack: Interlocking boxes may improve stability if the cartons are hard. If you decide to use this strategy, stack the boxes edge to edge and corner to corner for more strength.

Column Stack: Boxes or cartons are placed in straight columns without any overlap. To improve load stability, place together corrugated pads (also known as load protection pads) between the layers.

There’s also overhanging and pyramis stack methods, however, they’re not highly recommended as they increase the chance of damaging the shipment.

Last Minute Check

Last Minute Check

Before sending your package on its journey, double-check everything again. Check that you have created a stable load. Check the box again, and ensure everything is properly taped and the labelling is clear. If everything seems in order, it’s time to send the package.

Of course, packing is not rocket science; however, it requires a thoughtful approach. The packaging process is the same whether it’s a big or small item. Prepare the right materials in advance, follow our steps, and your cargo will be packed in no time.