Boxed and Loaded

6 Ways to Package and Ship more Efficiently

Space matters from the moment a product is boxed to the way it’s stacked on a pallet and loaded onto a trailer. Making smarter packaging decisions along the way can cut freight costs, speed up handling, and improve overall efficiency.

1.Match the Box to the Product

Did you know that the average package contains 24% empty space? Companies that optimize box sizes can cut shipping costs by as much as 35% by selecting the best-fitting outer packaging.

• Pick the smallest box that fits without crushing or overfilling to reduce void space and filler.
• Choose dimensions that stack efficiently to get more from your pallet and trailer space.
• Opt for alternative packaging (poly mailers, padded envelopes, or corrugated pads) for soft, flat, or non-breakable items to reduce bulk.

2. Optimize Internal Packaging

Choosing the right outer packaging is only half the job. Internal packaging is important for protecting product, minimizing weight, and maintaining box integrity for stacking. The better the pack, the stronger the box, which means safer pallets and fuller trailers.

• Void fill: Use materials like paper, air pillows, or foam to eliminate movement without adding excess weight.
• Cushioning: Protect fragile items with bubble packaging or paper pads to prevent breakage during transit.
• Securing: Use tape, ties, or dividers to keep contents in place and maintain box strength.

3. Build Better Pallets

Gaps, misaligned boxes, or unstable stacks waste trailer space and slow down handling. Standardizing stacking methods can improve trailer utilization by up to 30% and reduce the total number of shipments.

• Standardization: Keep pallet loads uniform in height and shape when possible to speed up loading, improve trailer planning, and safeguard product integrity.
• Stacking: Use consistent patterns like column stacking for strength, interlocking for mixed loads, or double stacking. Consider slip sheets, top frames, or reinforced cartons to increase trailer density.
• Alignment: Match pallet footprints to trailer dimensions to reduce overhang and wasted space.
• Height: Stack to full pallet height when safe to maximize vertical space.
• Securing: Wrap loads tightly with stretch film to prevent shifting or collapse in transit.

4. Determine Shipment Type

The right shipping format is just as important as choosing the right box. Matching product type to shipment type reduces waste and minimizes touchpoints.

• Less-Than-Truckload (LTL): Ideal when freight fills less than half a truck’s space. Shipment is combined with others heading to nearby destinations, which reduces costs but involves more handling, increasing risk of damage or delays.
• Full Truckload (FTL): Best for larger shipments that fill most of a trailer, leading to faster transit times, less handling, and a lower cost per unit.
• Parcel vs. Freight: Consider whether multiple parcels would be better combined into a palletized freight shipment.

5. Maximize Trailer Loading

How pallets are placed inside the trailer affects freight density, helping reduce trips and maximize ROI.

• Align pallet dimensions with the trailer layout to avoid wasted edge and corner space.
• Use full trailer height by stacking stable, well-secured pallets to utilize vertical space.
• Distribute heavy and light pallets evenly to prevent tipping and axle issues.
• Use filler loads, corner braces, or load bars to eliminate air gaps and prevent shifting.
• Arrange pallets by delivery order or zone to speed up unloading and reduce on-site time.

6. Reduce Touchpoints

Fewer handoffs mean fewer delays, errors, and damaged goods. Smart packaging and automation streamline movement from pack line to delivery, saving time and cutting labour costs.

• Automation: Use packing systems to select the right box size, apply tape, and insert void fill efficiently.
• Pre-labelling: Apply shipping labels and sort packages by destination during packing to streamline warehouse and receiving processes.
• Standardization: Use consistent box sizes and formats to simplify movement on conveyors, shelving, and scanning during processing.

Our experts are here to help! Whether it’s adjusting box sizes, exploring automation, or customized engineering solutions, we’ll work with you to maximize space and minimize waste. Contact us to get started!