Protecting rolled products from damage is one of the more challenging jobs for unit load material handling.

If you work with heavy rolls of foil, film, paper, plastics or other high-value material, you know that damage during transport or storage can make the product unusable. That's a costly mistake no one wants to make.

Shipping Roll Products

To develop a better protection system for transporting factory rolls, everything from the roll properties to customer requirements must be considered. A minor dent is not so minor when it causes thousands of dollars in loss. Equally cringe-worthy is a load that shifts during transport and causes product to open or roll away.

There are three main ways to ship rolled products:
  

1. Vertical Rolls
   Vertical Rolls put the least stress on a pallet or platform. This solution is best suited for rolls that can handle being shipped in a upright position. Advantages include lower-cost pallets and minimal unitizing to keep the roll(s) secure on the pallet.
   
   
2. Cradle Supports
   Cradle supports work best when rolls can withstand pressure from the pallet or packaging and can ship in a horizontal position. This option requires more pallet support and some type of "cradle" to hold the roll secure. Made from wood, plastic, foam or paper, cradles can be permanently attached to the pallet or added at time of shipping.
   
   
3. Suspended Rolls
   When rolls cannot withstand pressure from the pallet, they are suspended. Roll cores are typically attached to header boards at each end to keep the roll suspended above the pallet. While this is the most protective shipping method, the strength and stiffness requirements for the pallet are much greater. Extra nails, wider boards at tine tips and other securement reinforcements help prevent any part of the pallet from touching the roll during handling.

Maximize Protection while Minimizing Cost

If you are experiencing too many callbacks due to roll damage, it may be time for a change. And not just for damage control. Shifting over to a better roll pallet design can also save time by streamlining the palletizing process. Delivering products on time and in pristine condition saves money plus offers a competitive advantage.

Air freight is the creme de la creme of all shipping methods and comes with a hefty price tag. But, can choosing the right pallet for air shipments really help "lighten the load"? Yes. Yes it can.

Choose the Right Air Freight Pallet

Air freight can be expensive. But cost-conscious businesses with lean inventory often depend on air freight (instead of ocean) to move product in a timely, more predictable manner. So how can these businesses optimize air freight cost? Easy. Consider these money-saving air freight tips:
  

• Follow Industry Standards
  By industry standards, I mean shipping on an ISPM-15 exempt pallet. All plastic pallets are inherently compliant with export regulations so they eliminate the need for stamping and documentation. This makes exporting hassle-free and lessens the chance for freight delays.
  
  
• Go Light
  You know how you get charged for that extra suitcase when you fly on a trip? Well, that's what airlines call chargeable weight and it applies to cargo too. It is calculated using weight and dimensions. The lightweight nature of plastic pallets makes most of them export friendly. So choosing a 15 lb plastic pallet over a 35-40 lb pallet is really going to save you some money.
  
  
• Think Nestable
  Nestable pallets tend to be lighter in weight and cost less. This is especially important to consider when the pallets are shipping one-way and are not expected to return. When not in use, nestable pallets take up less space to save money in storage and transport costs. 
  
  
• Add Optional Runners
  Need more support? Some loads require more secure stacking capabilities when shipping via air cargo. A popular option for creating a flat and safe surface is to snap on runners to the bottom of nestable pallets. This still keeps the pallet weight and price down but adds stacking and racking capabilities.
  
  
• Get Size Advice
  Size matters. Plastic pallets have consistent and precise sizing and weights to make calculating your loads easier. Not only that, they come in many sizes to work with your application. The right size can prevent cargo damage and save money.
  
  
• Ask About Used
  New isn't always better. There is a huge selection of used plastic pallets that are ideal for export. Used pallets are structurally sound and typically have only some minor cosmetic damage. Best of all, they cost less.

  
Reduce Headaches and Save Money

Shipping air freight can be an expensive headache. Using the wrong pallet for export could be costing more than you realize. Getting expert advice for choosing the right plastic pallet really can help make the process easier and cheaper.

Have a question about choosing the best pallet for your air freight application? Post it here.

Post by Lindsey Silverman, Business Development Representative

Recycled wooden pallets or remanufactured?

​It's a question that comes up often. Before we get into which pallet is better for your packaging needs, let's sort out the definitions of recycled vs remanufactured.

​Defining Recycled vs Remanufactured

Buying wooden pallets starts with understanding the industry lingo. If you're just beginning your search, you're learning that not everyone speaks the same language. Worse, many of the terms sound confusingly similar. Below are the most common interpretations:

Recycled Pallets

Recycled wooden pallets are repaired quickly without complete deconstruction. The mending results in a pallet similar to the original design. Recycled pallets may also be called:

• Repaired Pallets
• Refurbished Pallets
• Reconditioned Pallets

Remanufactured Pallets

Also called reman pallets, these are completely rebuilt using dismantled boards reclaimed from unrepairable wooden pallets. A variation of reman pallets are built using a mix of old and new materials. Alternate names for both varieties of remanufactured pallets include:

• Rebuilt Pallets
• Hybrid Pallets
• Combo Pallets

​Choosing Between Recycled and Remanufactured Pallets

Recycled and remanufactured wooden pallets each have their own advantages. Recycled pallets tend to be cheaper. Reman pallets offer design flexibility. Your unique packaging requirements will determine which one is best.

Choose Recycled Pallets

Recycled pallets are easiest to find in industry standard configurations and sizes. They are typically sorted by size and grade. Choose recycled pallets if your load safely fits within the guidelines for an industry-specific pallet. Common examples of recycled pallets include:

• GMA Pallets
• EPAL Pallets
• CP1 Chemical Pallets
• CP3 Chemical Pallets

Choose Remanufactured Pallets

If your load exceeds the weight or size guidelines of a more readily-available pallet, choose remanufactured. Reman pallets can be custom built to adjust the spacing or length of deckboards. Have a lighter load? Ask about money-saving designs engineered to use less lumber. The point is that reman offers almost endless opportunities like these:

• 48x40 with Special Top Deck Spacing
• 48x31 Built Only with Reclaimed Wood
• 72x36 Built using New Stringers and Used Deckboards

A Smart Choice in Pallets

Now that you know what we mean by recycled and reman pallets, it shouldn't come as a surprise that most wooden pallets in circulation are not new. Repairing and rebuilding is a smart choice for saving money and reducing waste. While heavily-regulated industries might not be a good fit, most pallet users can benefit from using recycled and remanufactured pallets.

Do you have recycled or remanufactured pallet success story? Share it here or ask about ways for creating a new success story.

Post by: Jonathan Haynes, Regional Sales Manager

Here we go again. If you thought 2013 was a bad year for industrial lumber availability, 2018 may make five years ago look downright mild.

Lumber Prices are Going Up

Crisis breeds opportunity, or so they say. Here are increases we've already seen in raw materials:
​  

• Softwood Composite
  Prices are up about 34% in the last 12 months
  
  
• Hardwood Pallet Cant Composite
  Prices are up 11% in the last 5 months

Right now, lead times for industrial lumber are extended and supplies are tight. This means wooden pallet and crate prices have to go up.
  

How to Save on Pallet and Crate Costs 

I'm being asked all the time if anything can be done to combat these price increases. The answer is, yes! Retrieval programs for pallets and crates can save your company 10-50%.
  

• Take Back Control of Costs
  A pallet and crate retrieval program transfers the cost control lever back to manufacturers and shippers. Start by looking at all operating costs with a focus on cost-per-use.
    
• Reuse Existing Packaging
  You might be surprised to learn that return programs do not have to be all inclusive to save money for the shipper. Existing packaging is almost always reusable in its current state.
  
  
• Reduce Packaging Waste
  It gets better. You'll help stop wood-based packaging from going into the landfill. Your company gets to reduce its carbon footprint while also saving money.

  

Change your Packaging from Expense to Depreciable Asset

Need even more reason to consider a packaging return program? The US economy is growing and so is demand for lumber. Logging and sawmill capacity has not yet caught up - and may not. Inflation is real and will grow as the economy grows. If there has ever been a time to get with a program and take control of packaging costs, this is it.

If a packaging return program isn't your best match, here are 3 other money-saving solutions to help with the rising cost of wooden pallets and crates.

As the cost of lumber continues to rise, how are you preparing your business for increased packaging costs? Share your strategies or ask questions in the comments below.

Post by: Rich Reiher, Vice President

Paying an arm and a leg for pallet freight these days? What if you could get 3 truckloads of rackable pallets delivered for the price of one traditional load?

Make the Most of your Freight and Floor Space

Traditional rackable pallets only fit about 500 per 53' truck. The same 500 pallets take up valuable space on your warehouse floor as they only stack 17-18 pallets high. The new RackNest plastic pallet fits 1,800 per truckload and 60 pallets per stack.

• ​Save BIG $$$ on freight
  Say you're paying $1,000 freight for a load of traditional rackable pallets and you can only fit 500 per truck. That's $2.00 freight per pallet. Now consider the RackNest... $1,000 freight / 1,800 per truck = $0.55 per pallet. It would cost you $3,600 to get 1,800 traditional rackable pallets delivered. You just saved $2,600 in freight!
     
• Fit 3 times as many pallets on the floor
  Instead of having 30 stacks, 16-17 pallets high, with the RackNest you will have 30 stacks, 60 pallets high. That's around 1,300 more pallets in the same space!
    
• Order less often and always be ready for a spike in production
  We all wish we could have multiple truckloads of rackable pallets on hand just in case production picks up unexpectedly. With the RackNest, when you order one load you'll get 3X more than you currently get. That's plenty for normal usage as well as any surge that may come down the line.

No one likes getting caught in a jam. If you're wondering if you can just wait out rising freight rates and increasing lead times, check out this article on a nationwide shortage of trucks from the Wall Street Journal.
​  

​In previous discussions about pallets, I touched on the nature of the load that a pallet might be expected to handle. If you are a pallet geek like me, the term “unit load” is often used to describe the goods that are configured in such a way as to be easily handled by that pallet.

​So, I guess the unit load is and has always been associated with pallets, right? Well, not exactly. Although we can trace the use of pallets all the way back to ancient times, the common use of pallets to handle the unit load did not get going until World War II.

​Why is my 2x4 lumber not 2 inches by 4 inches?

Many decades ago, lumber purchased from a sawmill physically matched the common dimensions we use today. So why does that pine or spruce 2x4 from your local lumber yard now come up short? The short answer is modern surfacing and shrinkage.

Over time we've come to accept these nominal (approximate) dimensions as standard. But there's still a catch. Shrinkage can be highly variable. This makes it very difficult to manage and regulate dimensional accuracy.

Rules for Calculating Dimensions

​So now you know that 1x3, 2x4 are 4x8 are really just names or nominal dimensions. But... it gets even more complicated. Dimensions change based on the width or the thickness. Here are the general "rules" for calculating softwood dimensions:
 
Nominal vs Actual Dimension Rules

​Dimensional Lumber

Softwoods (pine, spruce, fir, etc.) are generally known as framing or dimensional lumber. This wood is commonly used for framing walls and floors in our homes and regularly used for building wooded crates and pallets. Since no one likes unexpected dimensional errors, the handy chart below outlines the changes in dimensions you can expect:
​
Dimensional vs Actual Lumber Chart for Dried Softwoods

Regulating Lumber Dimensions

​The US Department of Commerce standardized softwood dimensions for green and finished lumber back in 1969.

Today, regulating dimensional accuracy in the US falls under the responsibility of the National Institute of Standards and Technology (NIST). The current standards are published by the government in a document titled the American Softwood Lumber Standard (PS 20). The latest version is labeled the Voluntary Product Standard PS 20-15.

Why is regulation so difficult?

State and local inspectors spot check lumber dimensions at mills and retail locations but determining if softwood boards are within limits is complicated. Here's why:​
​  

1. Shrinkage
   Green lumber has higher moisture content. As the wood dries (either in an oven or air dried) the dimensions reduce. Depending on wood species - and specifically wood grain direction - shrinkage can range from 2% to 15%. This equals anywhere from 0.012” to 0.6" for a 4 inch board.
    
2. Surfacing
   Boards with smooth sides are said to have a dressed surfaced. The process of smoothing out board surfaces further reduces the original width or thickness. Dimensional lumber is commonly labeled S4S. The designation stands for "surfaced 4 sides".
     
3. Inconsistent Testing
   Inspectors do not have nationally agreed-upon testing procedures. Everything from an individual inspector's sampling protocol to the device used for measuring can muddy the results. That's about to change.

 
If you're wondering about hardwoods, thickness measurements are slightly different, but most hardwood widths follow the softwood standard. As an example, a 6 inch hardwood board is actually 5.5".


New Testing Procedures Under Review

The Office of Weights and Measures (OWM) at the NIST has been working with the American Lumber Standards Committee (ALSC) since 2016 to develop new testing procedures for dimensional accuracy. The next big step in moving the new procedures forward is expected by summer 2018 when the proposal goes to a vote.

Have you ever wondered about about the impact of lumber's dimensional accuracy on wooden pallets and crates? Have your own wrong-size lumber story? Talk to me in the comments below.

Post by: Kent Longardner, Technical Sales Manager

Will a return program transform your expendable packaging expenses into reusable packaging assets?

Start by asking yourself four key questions about your packaging usage and distribution system.

4 Questions to Ask about Reverse Distribution

Reverse distribution is the process of managing the tracking, return and refurbishment of assets from your distribution chain. Put simply, you save money by returning pallets, crates and other packaging to be used again. As an added benefit, return programs reduce the disposal burden for your customers.

Is it for you? Let's find out:
  

1. Do I have enough volume?
   The more assets (pallets and crates) that pass through your system each year, the better. While there is not a minimum, more assets typically mean greater economies of scale and more savings. That said, smaller volumes can offer benefits too. Read on.
      
2. Can I ship enough each trip?
   Plain and simple fitting more returned packaging on each truckload reduces your per-unit freight costs. While returning a full truckload of packaging assets often works best, returning 20 crates in a trip can make sense too. The next questions explain further.
     
3. Is my return distance close enough?
   Again, freight costs come into play here. Obviously, the less distance your assets travel, the better savings opportunities you have. But, it's not as simple as distance. Even returning assets from another country can produce benefits. That brings us to the last question.
     
4. Is my asset valuable enough?
   High-value custom pallets and crates offer some of the best opportunities for a successful return program. However, assets of any value have the potential to work if other factors from above also work in your favor.

Finding Cost Savings

As you can see, the decision to implement a pallet return program is not straightforward. Not to worry. A reverse distribution expert can easily show you the unique opportunities your system has to save.

In many cases, the savings comes from places you haven't yet considered. Return programs can include a variety of transport products including pallets, skids, crates, packaging, parts, u-channels, straps and more.

Should you be returning assets? Finding out is easy. Start by telling us about your system or ask us a question for free.

Post by: Kent Longardner, Technical Sales Manager

Plastic lumber offers captive pallets a new future.

Captive pallets are designed to save money by being reusable. Plastic lumber is repairable and durable. Plus, it can be custom made to fit your specific requirements. Sounds pretty good so far. But will it work for you?

Below we explore the benefits and drawbacks to plastic lumber pallets.

Comparison to Traditional Wooden and Plastic Pallets

Captive pallets are pallets designed to last in a warehouse environment for repetitive use. Both traditional wood and plastic pallets are used in these applications.

• Heavy duty plastic pallets have become popular as a captive pallet in many industries. Unfortunately, they do not fit the needs of all customers because custom sizes and designs can be cost prohibitive.
    
• Wooden pallets are less expensive to produce and can be repaired when minor damage has occurred. Even though wood is often used for captive pallets, they can be easily damaged, require mold prevention treatment and can’t be easily sanitized.

Is Plastic Lumber Right for You?

The biggest advantage of a plastic lumber captive pallet is custom design. Custom designs are often worth looking at because they can uncover hidden savings.

A design team is critical to the this process. In addition to drafting a new design, the team reviews all supply chain systems to make sure the pallet will work with all material handling equipment. Utilizing a service such as the Nelson Tech Center provides expertise for reducing total cost of ownership and improved sustainability.

Here are some pros and cons to consider:

Benefits of Plastic Lumber Board

• Durable
• No moisture problems (reduces mold and decay)
• Cleanliness
• Can be nailed using the same equipment as wood pallets

Drawbacks of Plastic Lumber Board

• Higher initial cost
• Boards must be nailed or screwed together using metal fasteners
• Weight (plastic lumber can be heavier than most wood species)

    
Captive pallets have undergone many changes in the last 50 years - especially with the introduction of plastic pallets. While plastic pallets do not fit every need, the introduction of plastic lumber provides a new option for a custom-sized captive pallet.  

In what ways could a captive pallet made from plastic lumber work for you? Share your thoughts in the comments below.

Post by: Jonathan Haynes, Regional Sales Manager

​What makes a pallet rackable? Well, we've been spending some time on that question including getting into pallet structure, material stiffness and the seven racking systems we most commonly find in industry. 

Part of the discussion included assigned load ratings. In most cases, rackability ratings assume the pallet can safely bridge a span between supporting structures. The ability to dependably and securely bridge that span is what makes a pallet rackable.

Nature of the Load

A common standard for rackability is 2200 pounds or about one metric ton. But what about that ton? Is a ton of feathers the same as a ton of lead? Well, we know they both weigh the same but their nature is very different. And it is the nature of the load that also needs to be considered when determining the suitability of any pallet for its intended use.

A Stiff Load can Increase Functional Racking

If we were to make a stack of 40x48 sheets of 3/4 inch plywood on a pallet, it might end up being very heavy. Think about the last time you got an unassembled piece of furniture from IKEA. Holy smokes that stuff can be heavy! But, because our stack is stiff and spreads the load over the entire surface of our pallet, the load actually helps impart stiffness to the pallet. So even though it is very heavy, this type of load increases the functional racking load rather than challenging it!

By contrast, if the load is not in of itself stiff, it can cause a problem. Yep, even if we evenly spread the load across the surface of a pallet. Now what? Well, unitizing a load with stretch wrap can take a challenging load and make it less so. The stretch wrap makes the load stiffer, more like our stack of plywood. But, no matter what, our stack of plywood will always be stiffer than say, small bottles shrink wrapped in bundles and stacked on a pallet.

Challenging Loads

In addition to our example of stacked bottles in stretch wrap, here are some of the more common challenging loads for rackable pallets:

• 5 gallon pails
• Steel or poly drums
• Bulk bags
• Smaller bags of seeds or beans
• Any single heavy item placed in the center of the pallet
  see my story below on this one...

Story time... I was once shown a 3,500 lb lift truck counterweight and asked to propose a pallet to handle it. I had a GREAT solution. Of course, the picture in my mind is the weight laying flat on its back and spread out over the surface of the pallet. I sent over a sample pallet and was mortified when I got an email showing the pallet in total failure! What happened? The counterweight was placed upside down with only three 4x4" points of contact on the pallet. Heaven knows what the PSI must have been on those three points, but I can tell you the highly-rated pallet folded like a cheap camera!

Getting it Right the First Time

To recap, the nature of the load must be considered when determining the suitability of a pallet for any given application - especially if it is said to be "rackable".

Load rating will generally assume the loads will be:

1. Unitized
2. Distributed evenly over the surface of the pallet

But even then you need to ask yourself the right questions. For example, will we be moving a ton of feathers or a ton of lead? The answers will help you get it right the first time.

If you want help with your load questions, ask a pallet professional or please post them below. And watch for my next post on the history of the unit load and how we got here in the first place.

Post by: Hartson Poland, Business Development - Plastic
Use of metal racking photo used with permission from our friends at Warehouse Rack & Shelf, LLC.
Use of  Forklifts in Warehouse photo by Mdornseif licensed under the Creative Commons Attribution 3.0 Unported license.