Logistics is the golden thread that connects all the essential parts of your business. It impacts your customer satisfaction, time to market, and overall efficiency, so you should be particular about the transport options you choose. How you load your containers is just as important as the vehicle that moves them.
Today, we explore and compare two distinct freight packing methods: floor loading and pallet loading. Understanding the difference between these two systems can help you optimize each delivery for speed, ease of handling, and cost.
What Are Floor-Loaded Containers?
Floor loading is a method of packing trucks and shipping containers that does not involve pallets. Instead, the cargo is packed directly onto the floor of the container to maximize space. Items are stacked individually (or in boxes) directly on top of one another, filling the container top to bottom and side to side.
Benefits of Floor Loading
- Load more items per shipment.
- Maximise container space to reduce costs.
- Allow for flexible packing arrangements.
Drawbacks of Floor Loading
- Longer loading and unloading times.
- Increased risk of cargo damages.
- Demanding manual work increases labor costs.
What Are Palletized Containers?
Palletizing involves packing items onto pallets before loading them into a truck or shipping container. The pallets are wrapped and bar-coded to facilitate sorting and inventory management. Pallets create platforms that raise cargo off the floor of the container, providing structural stability for stacks of boxes.
Benefits of Pallet Loading
- Easier handling for warehouse staff.
- Reduced loading and unloading times.
- Better protection of goods against damage.
Drawbacks of Pallet Loading
- Reduced container space utilization.
- Increases packaging costs—pallets, shrink wrap, etc.
- More preparation is required to pack and label pallets.
Compare Floor Loading vs Pallet Loading
Both floor-loaded and palletized containers have value in logistics. It’s knowing how to choose between the two methods that makes the difference. The comparison table below highlights key factors to consider when choosing between floor-loaded and palletized freight.
| Floor-Loaded Freight | Palletized Freight | |
| Product types | Best for heavy, bulky or odd sized items like furniture or appliances and boxed cargo that has unique dimensions. | Better for small or fragile cargo such as electronics or boxes of the same size and shape. |
| Shipment size | Tighter stacking allows you to pack more products per load. | Pallets take up space and create gaps that reduce the shipment volume. |
| Handling time | Manual and labor-intensive – takes more time to load and unload. | Forklifts make loading and unloading much faster. |
| Overall costs | May be more cost-effective, although the labor cost may be higher. | It may be more expensive due to the need for extra materials and not maximizing container space. |
Palletized vs Floor-Loaded Containers – Additional Considerations
The cargo you’re transporting is not the only thing to consider when choosing between floor-loaded and palletized containers. Your business dynamic also plays a role. Don’t forget about the Three W’s below.
1. Wastage
What is your company’s attitude towards waste? Consider the environmental and cost impact of using pallets versus the waste that may arise from damaged products. While some waste is tolerable, you should aim to minimize it wherever possible. Your waste management strategy should be tailored to the loading method you select.
2. Warehouse Set Up
Stacking a floor-loaded container is a manual task that can be made more efficient with the use of conveyor belts or gravity rollers. Even if you don’t use machinery now, you may want to expand in the future – and your warehouse will need extra space. You’ll also need to dedicate larger loading and packing zones compared to palletized shipping.
On the other hand, if you use palletized containers, you’ll need to source forklifts with trained operators. Your warehouse will need dedicated forklift lanes with compliant turning circles – this may require third-party warehousing services.
3. Workforce Capacity
Working with floor-loaded freight is more labor-intensive and time-consuming. And if you have a small team, you run a higher risk of shipping delays. Sometimes, working with pallets could make more sense, even though the initial cost is greater. However, preparing pallets for transit adds complexity that may increase your workload (depending on your business model).
Still not sure which system to choose? Meyer’s fulfillment services can help you implement the best shipping method for your needs to help you advance your business goals.
Can You Combine Both Methods?
Many business owners ask us whether they can use a mix of pallets and floor loading for their shipments. The answer is yes but with caution. How you pack a container often depends on the destination of your shipment. Always check with the receiver on their shipping preferences before preparing a mixed load.
If you have a large container, it may be possible to palletize some items and stack others on the floor. However, the cargo’s weight should be evenly distributed to prevent damage. Using a mix of pallets and floor-loaded stacks may also create gaps that reduce space usage efficiency.
Understand the Floor Loading Process
Floor-loaded freight takes careful planning and preparation to prevent damage. Loading is a manual process that requires a high degree of competence and coordination. Here’s the process at each stage:
- Load planning – calculating the weight distribution and choosing an appropriate stacking configuration for your shipment.
- Staging – the cargo is arranged near the container in the order it will be loaded. The heaviest, bulkiest items typically end up on the bottom, with lighter boxes on top.
- Loading – floor-loaded containers typically receive a sheet of plywood or other protective base layer before cargo is loaded. Then, workers load the boxes one by one, stacking them tightly against the sides of the container, leaving no gaps.
Understand the Pallet Loading Process
Loading palletized containers may be physically easier, but it requires just as much preparation, if not more, than floor loading. Each pallet should be treated as an individual container, loaded with weight restrictions and stability in mind.
- Pallet preparation – choosing the correct pallets based on industry standards and recipient requirements. Packing, loading, and labeling the pallets to make sorting easier at the destination depot.
- Batch staging – pallets are staged similarly to individual boxes. However, because the items are bundled together, staging is much faster.
- Loading – workers use forklifts to move the pallets into the container and pack them neatly from end to end. Pallets may be stacked to increase space utilization.
Weight Limitations for Pallets vs Floor-Loaded Containers
Adhering to weight restrictions is crucial. It protects your business from overloading fines and protects your shipment from damage. Floor-loaded and palletized containers have different weight limitations that need to be considered.
Floor-loaded containers
- Maximum container weight
- Strength of the container floor
- Manageable weight for human laborers
- Legal road limits on weight
Palletized containers
- Maximum container weight
- Weight rating of individual pallets
- Forklift weight rating
- Legal road limits on weight
Restrictions Based on Shipment Destination
You cannot plan an effective loading strategy without checking the shipping requirements set by the consignee. Some destinations have different rules and restrictions. For example, many large retailers, including Amazon and Walmart, typically only accept palletized loads.
Floor loads are typically only allowed for smaller shipments or where it is safe for workers to unload manually. Make sure your fulfillment services provider understands the details of your shipping destination before selecting a loading strategy.
Find the Best Shipping Strategy for Your Business
At Meyer, we understand the importance of maximizing space to optimize shipping costs. Our approach is not limited to surface-level solutions. Instead, we take the time to understand your business and develop a logistics strategy that suits your long-term goals.
We can help you weigh your operational priorities when choosing between floor-loaded and palletized freight. Our experienced team is backed by a legacy of over 100 years in the logistics and relocation space. For more information about our warehousing, fulfillment, or pallet storage services, please get in touch.