Optimizing pallets is almost kind of like tetris, or packing the family car for a trip to make sure ALL of the luggage fits. Maximizing Pallet loads begins at packaging design and sometimes the product stage.
I’ve gone back to modify product footprints to optimize shipping costs. I always start my process with paper and a pencil to sketch out the configurations first.
Understand your palette requirements (Standard US is 48L x 40W x 48H - but always confirm)
Plan based on your logistics requirements
Configure dimensions to maximize inner cartons and outer/master cartons
Use Pallet configuration software and coordinate closely with your factory and shippers on finalizing the details
Confirm your customer’s shipping requirement
Coordinate with your freight forwarder for any specification coordination
Eliminate inners when possible and opt for stronger e-flute outer/masters for protection
Build out to maximize freight and warehouse costing
be a good global citizen and eliminate unnecessarily large packaging footprints
consider packaging size for shipping costs for direct to consumer and online
The end actually drives the beginning. Product design starts from the peg hook or shelf on out.
The old rule was that the requirements of retail real estate often designates your logistics decisions. That’s evolved slightly, while Amazon’s a huge driver in how we evolve our selling - we still need to consider brick and mortar footprints. Measure twice and cut once. #Maximize.