Pallet optimisation

Our customer approached us to find a solution to optimise the volume of packaging per pallet, per delivery to optimise both pallet and truck space.

The pack was not to be compromised in anyway; it was still essential to protect product and a re-design was not the preferred option due to a familiarity with the current pack.

After researching the options available, we decided that a change of board grade would be the best possible solution.

The current C flute solution meant that the current inbound delivery of C flute cases sized 350x250x246mm was 560 cases per pallet. This resulted in:

◦ 52 pallets per trailer (when double stacked full loads), results in 29,120 cases per trailer

◦ An 800,000 annual case requirement equates to 1,429 pallets and 28 trailers for deliver

Changing the board grade to M flute and an altered pack size delivered:

An increased inbound pallet quantity of 840 cases (up 50%) by changing the pack size to 350x244x238mm

This resulted in 52 pallets per trailer (when double stacked full loads equating to 43,680 cases per trailer

Our customers 800,000 annual case requirement means 953 pallets (476 less) and 19 trailers for delivery (9 less)

• Pallet space maximised – Simple design amend
• Increased truck load capacity – More packs per pallet, more pallets per load
• Uncompromised pack quality  – Design team applied material and product knowledge

The Impact

The customer achieved storage, transport and cost efficiencies and were delighted with the result