Knowledge

Unit load

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28: 2133: 20: 301:(1,814 kg) to limit the stresses on handling equipment. They are weatherproof, and stack 16 ft (4.877 m) high. They often use steel pallets, steel straps with notched seals, outdoor plywood, and plastic film. MIL-STD-1660 mandates that loads must never be less than the width of a pallet, while permitting some overhang. The markings are LOGMARS 222:
Unit loads move via an unpredictable combination of many types of vehicles and storage areas, and the exact set is difficult to predict. Therefore, unit loads must be designed to travel by any such vehicles, and be stored in a wide variety of places. There are many similarities in the requirements
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MIL-STD-1660 at first looks like overdesign to commercial unit-load designers. However, similar marking standards, safety, stability, volumetric efficiency, weight limits and impact resistance are routinely needed in commercial logistics. Sling handling is routine for small ports and noncontainer
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Companies must now consider sustainability when determining how their packaging products will be reused or recycled at the end of their journey. By combining sustainability with unit load science, they not only create the optimal unit load, but also reduce the amount of packaging material used to
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Considerable knowledge exists regarding the design of each of these components: their interactions have more recently been studied. When packaging, pallet, and handling systems are designed separately at different locations by different teams, the result might be inefficient unit load systems.
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and standard inventory numbers. The standard describes major parts of the logistic path, including storage, ship, air, truck, forklift and sling (i.e. ship-to-ship and parachute). There are auxiliary standards for ship-to-ship transfers, and amphibious transfers. There are tests for stacking,
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Another standard for unit loads is MIL-STD-1660, a standard for ammunition unit loads. DOD unit loads generally use 40 in × 48 in (1,016 mm × 1,219 mm) pallets, which unfortunately do not pack efficiently into ISO containers. They weigh less than 4,000 lb
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Most consumer and industrial products move through the supply chain in unitized or unit load form for at least part of their distribution cycle. Unit loads make handling, storage, and distribution more efficient. They help reduce handling costs and damage by reducing individual handling.
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A systems-based approach to unit load design uses software tools and lab testing to create a package that uses just the right amount of material to protect the product, make for safe handling and transportation and minimize the use of non-recyclable materials.
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Systems-based design is a proven process of unit load component cost optimization based on an understanding of how the pallet, packaging and material handling equipment interact during product distribution and storage to design the unit load component parts.
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Standards provide institutional memory of the many conditions in real logistic trains, and collect the best practices for design and testing unit loads. Standards also describe load requirements, so that logistic providers can plan to meet them.
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transports. Weatherproofness could be optional. It is sometimes valuable, and the baggies are cheap. High, standardized stacking could be optional as well. It is expensive, but sometimes valuable for rackless and military customers.
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Material-based standards describe proven designs for particular circumstances. These are often used to describe unit load components such as pallets, strapping, seals, caps, retaining rings and battens.
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D4169 has standard test protocols for unit loads. These vary based on the value of the load, the expected hazards, and the distribution environment. This is a performance-based standard.
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Ward, R.E. 1993. Perspectives on material handling from the United States. Presentation at INTERMAX 93. Material Handling Industry of America, Charlotte, NC. www.MHIA.org.
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method of unit load design. Components are sometimes over-specified to get assured performance, or tested to get inexpensive economic performance.
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Often a few inexpensive additions to the packaging can stabilize or stiffen a critical part and give good unit-load performance at a low cost.
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refers to the size of an assemblage into which a number of individual items are combined for ease of storage and handling, for example a
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There are three kinds of unit load design: component-based, systems-based, and standards-compliant. These have different applications.
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standards describe needs and allow flexibility in the choice of materials. These are applied to particular unit load designs.
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transport, sling, forklift and pallet jack, impact, drop tests, tip, water-retention (i.e. weather), and safe disassembly.
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transport that load, maximizing the materials that can be recycled and minimizing what goes into a landfill.
2161: 1063: 384: 1952: 1836: 1068: 850: 269: 51:, or a container load represents a unit for shipping purposes. A unit load can be packed tightly into a 1595: 501: 2050: 2012: 1942: 1932: 870: 730: 657: 572: 1937: 1806: 1405: 825: 795: 685: 417:, U.S. DOD, Dept of the Navy, Naval Sea Systems Command, 8 April 1970, MIL-STD-1660, archived from 1967: 1590: 1510: 1370: 898: 535: 352: 108: 1686: 1395: 1098: 830: 810: 373: 146: 16:
Size of assemblage into which individual items are combined for ease of storage & handling
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The consequences of independent component-based design in the supply chain can include:
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Unit load storage and distribution systems consist of several interacting parts:
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Yam, K. L., "Encyclopedia of Packaging Technology", John Wiley & Sons, 2009,
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Systems Based Design Eliminates Product Damage, Pallet Enterprise, pg. 90
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MHIA/ANSI MH1–2005 Pallets, Slip Sheets, and Other Bases for Unit Loads
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for long-term storage and long-distance transportation of unit loads.
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permit a unit load to be designed and tested to meet a written
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Factors considered in unit load systems-based design include:
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load represents a unit load which can be moved easily with a
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to determine that the unit load is indeed effective.
479:"Designing The Better Unit Load From The Ground Up" 332:ASTM D6055 Mechanical Handling of Unitized Loads 2148: 31:Air cargo container of the AKH type on a trailer 588:Modified atmosphere/modified humidity packaging 23:Reach truck handling stretch wrapped unit load 536: 252: 335:ASTM D6179 Rough Handling of Unitized Loads 1722:Hazard analysis and critical control points 473: 471: 543: 529: 1632:Automatic identification and data capture 516:Virginia Tech Center For Unit Load Design 414:Design Criteria for Ammunition Unit Loads 242:Compression stress and product protection 130: 468: 437: 26: 18: 239:Interfacial friction and load stability 205: 135:Component-based design is the outmoded 2149: 407: 405: 524: 245:Vertical and horizontal stabilization 91:A typical unit load might consist of 1034:Flexible intermediate bulk container 230:Distribution vibration and resonance 402: 122: 13: 2018:Vertical form fill sealing machine 313: 201:Reduction of environmental quality 79:for sale to consumers or for use. 14: 2173: 1988:Rotary wheel blow molding systems 836:Purdue Improved Crop Storage bags 509: 2132: 2131: 1958:Mechanical brake stretch wrapper 1692:Electronic article surveillance 1546:Shock and vibration data logger 1391:Linear low-density polyethylene 1797:Radio-frequency identification 495: 459: 431: 272:to comply with a standard and 158:The distribution environment ( 1: 1908:Extended core stretch wrapper 861:Single-serve coffee container 550: 484:. Millwood Incorporated. 2011 447:US Forest Products Laboratory 396: 233:Load bridging and deformation 1064:Insulated shipping container 385:Less than truckload shipping 7: 1953:Material-handling equipment 1837:Verification and validation 1069:Intermediate bulk container 851:Self-heating food packaging 342: 195:Reduced handling efficiency 82: 10: 2178: 1596:Time temperature indicator 253:Standards-compliant design 155:Handling/storage equipment 2129: 2051:Environmental engineering 2026: 2013:Turntable stretch wrapper 1943:Lineshaft roller conveyor 1933:Injection molding machine 1845: 1614: 1244: 889: 871:Toothpaste pump dispenser 731:Disposable food packaging 676: 573:Child-resistant packaging 558: 1938:Label printer applicator 1807:Shearing (manufacturing) 1406:Low-density polyethylene 826:Pharmaceutical packaging 796:Low plastic water bottle 686:Alternative wine closure 198:Wasted natural resources 1968:Orbital stretch wrapper 1591:Temperature data logger 1511:Pressure-sensitive tape 1371:Humidity indicator card 899:Aerosol spray dispenser 353:United States Air Force 109:pressure-sensitive tape 1687:Die forming (plastics) 1396:Liquid packaging board 1099:Multilayered packaging 831:Plastic milk container 811:Optical disc packaging 374:Palletized load system 147:Packaging and labeling 131:Component-based design 32: 24: 2116:Sustainable packaging 2066:Life-cycle assessment 2046:Closed-loop box reuse 1993:Seed-counting machine 1326:Corrugated fiberboard 1276:Biodegradable plastic 999:Corrugated box design 653:Sustainable packaging 643:Shelf-ready packaging 618:Packaging engineering 358:Concrete masonry unit 268:. A unit load can be 236:Unit load deflections 93:corrugated fiberboard 30: 22: 2086:PET bottle recycling 1948:Logistics automation 1476:Plastic-coated paper 623:Resealable packaging 206:Systems-based design 192:High packaging costs 103:and stabilized with 57:intermodal container 2162:Shipping containers 2138:Category: Packaging 1973:Packaging machinery 1782:Product development 1581:Tamper-evident band 1421:Modified atmosphere 761:Foam food container 421:on 24 November 2007 288:Performance testing 95:boxes stacked on a 69:distribution center 2101:Reusable packaging 2061:Industrial ecology 1822:Ultrasonic welding 1787:Production control 1737:Injection moulding 1622:Aseptic processing 1331:Corrugated plastic 1201:Steel and tin cans 1171:Shipping container 1109:Packet (container) 846:Seasonal packaging 746:Evidence packaging 726:Currency packaging 721:Cosmetic packaging 628:Reusable packaging 390:Dimensional weight 349:463L master pallet 33: 25: 2144: 2143: 2106:Reverse logistics 2091:Plastic recycling 1963:Multihead weigher 1883:Cartoning machine 1878:Cap torque tester 1792:Quality assurance 1767:Plastic extrusion 1732:Induction sealing 1702:Extrusion coating 1561:Staple (fastener) 1531:Security printing 1366:Hot-melt adhesive 939:Biodegradable bag 781:Glass milk bottle 663:Tamper resistance 603:Package pilferage 578:Contract packager 438:Laundrie (1986), 328:978-0-470-08704-6 186:Unsafe workplaces 2169: 2135: 2134: 2121:Waste management 2111:Source reduction 1928:Industrial robot 1832:Vacuum packaging 1757:Package tracking 1712:Glass production 1672:Corona treatment 1662:Containerization 1526:Screw cap (wine) 1441:Oxygen scavenger 904:Aluminium bottle 856:Screw cap (wine) 801:Luxury packaging 633:Reuse of bottles 598:Package delivery 583:Edible packaging 568:Active packaging 545: 538: 531: 522: 521: 504: 499: 493: 492: 490: 489: 483: 475: 466: 463: 457: 456: 455: 453: 444: 435: 429: 428: 427: 426: 409: 123:Unit load design 2177: 2176: 2172: 2171: 2170: 2168: 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737: 734: 732: 729: 727: 724: 722: 719: 717: 714: 712: 709: 707: 704: 702: 699: 697: 694: 692: 689: 687: 684: 683: 681: 675: 669: 666: 664: 661: 659: 656: 654: 651: 649: 646: 644: 641: 639: 636: 634: 631: 629: 626: 624: 621: 619: 616: 614: 613:Package theft 611: 609: 606: 604: 601: 599: 596: 594: 593:Overpackaging 591: 589: 586: 584: 581: 579: 576: 574: 571: 569: 566: 565: 563: 557: 553: 546: 541: 539: 534: 532: 527: 526: 523: 517: 514: 513: 503: 498: 480: 474: 472: 462: 448: 441: 434: 420: 416: 415: 408: 406: 401: 391: 388: 386: 383: 380: 377: 375: 372: 369: 366: 364: 361: 359: 356: 354: 350: 347: 346: 337: 334: 331: 329: 325: 321: 318: 317: 311: 307: 304: 298: 296: 289: 286: 283: 282: 281: 277: 275: 271: 267: 263: 262:specification 259: 250: 244: 241: 238: 235: 232: 229: 228: 227: 224: 220: 216: 212: 200: 197: 194: 191: 188: 185: 184: 183: 180: 173: 169: 165: 161: 157: 154: 151: 148: 145: 144: 143: 140: 138: 128: 120: 118: 114: 110: 106: 102: 98: 94: 89: 80: 78: 74: 70: 66: 62: 58: 54: 50: 46: 42: 38: 29: 21: 2027:Environment, 1642:Blow molding 1571:Stretch wrap 1501:Polyethylene 1491:Plastic wrap 1481:Plastic film 1466:Paper pallet 1401:Living hinge 1306:Coated paper 1225: 1186:Spray bottle 1166:Security bag 1159:Water sachet 1149:Salvage drum 1144:Retort pouch 1049:Glass bottle 944:Blister pack 909:Aluminum can 876:Water bottle 776:Gas cylinder 751:Field ration 648:Shelf-stable 497: 486:. Retrieved 461: 450:, retrieved 446: 433: 423:, retrieved 419:the original 413: 308: 299: 293: 278: 256: 248: 225: 221: 217: 213: 209: 181: 177: 141: 136: 134: 126: 105:stretch wrap 90: 86: 77:retail store 36: 34: 1923:Heat sealer 1888:Case sealer 1762:Papermaking 1682:Die cutting 1647:Calendering 1551:Shrink wrap 1426:Molded pulp 1411:Meat diaper 1376:Kraft paper 1356:Foam peanut 1346:Double seam 1316:Coextrusion 1286:Bubble wrap 1266:Bail handle 1211:Thermal bag 1134:Plastic bag 949:Boil-in-bag 881:Wine bottle 866:Spray paint 821:Popcorn bag 816:Oyster pail 701:Beer bottle 266:test method 172:temperature 117:shrink wrap 45:pallet jack 2151:Categories 2003:Staple gun 1983:Palletizer 1873:Can seamer 1742:Lamination 1667:Converting 1556:Slip sheet 1471:Paperboard 1336:Cushioning 1296:Cellophane 1271:Bioplastic 1249:components 1236:Wooden box 1206:Tetra Brik 1129:Paper sack 1104:Multi-pack 1054:Gunny sack 924:Bag-in-box 891:Containers 756:Flour sack 741:Egg carton 716:Coffee bag 696:Banana box 638:Shelf life 488:2024-01-29 425:2008-01-01 397:References 101:slip sheet 73:wholesaler 2157:Packaging 2096:Recycling 1903:Drum pump 1846:Machinery 1697:Extrusion 1615:Processes 1586:Tear tape 1576:Susceptor 1566:Strapping 1521:Screw cap 1496:Polyester 1341:Desiccant 1245:Materials 1226:Unit load 1181:Skin pack 1124:Paper bag 994:Clamshell 736:Drink can 668:Wrap rage 552:Packaging 465:Ward 1993 303:bar codes 274:validated 258:Standards 164:vibration 113:strapping 53:warehouse 37:unit load 35:The term 2029:post-use 1918:Heat gun 1868:Calender 1777:Printing 1606:Velostat 1601:Tinplate 1436:Overwrap 1361:Gel pack 1351:Flip-top 1256:Adhesive 1191:Squround 1094:Mesh bag 1079:Jerrycan 1024:Envelope 964:Bulk box 841:Sand bag 806:Milk bag 791:Juicebox 706:Box wine 679:packages 343:See also 270:verified 168:humidity 83:Function 1752:Molding 1657:Coating 1652:Canning 1311:Coating 1301:Closure 1059:Inhaler 914:Ampoule 786:Growler 677:Product 559:General 452:7 April 174:, etc.) 65:boxcars 2136:  2071:Litter 1913:Filler 1456:Pallet 1154:Sachet 1019:Endcap 984:Carton 979:Carboy 954:Bottle 934:Barrel 561:topics 326:  152:Pallet 137:ad hoc 97:pallet 55:rack, 41:pallet 1461:Paper 1381:Label 1281:BoPET 1004:Crate 482:(PDF) 443:(PDF) 160:shock 75:, or 61:truck 1291:Bung 1231:Vial 1221:Tube 1119:Pail 1014:Drum 989:Chub 974:Case 969:Cage 454:2020 368:IPPC 324:ISBN 295:ASTM 1386:Lid 1247:and 1089:Keg 1084:Jug 1074:Jar 959:Box 929:Bag 379:ULD 264:or 115:or 99:or 63:or 47:or 2153:: 470:^ 445:, 404:^ 170:, 166:, 162:, 111:, 107:, 71:, 59:, 544:e 537:t 530:v 491:.

Index



pallet
pallet jack
forklift truck
warehouse
intermodal container
truck
boxcars
distribution center
wholesaler
retail store
corrugated fiberboard
pallet
slip sheet
stretch wrap
pressure-sensitive tape
strapping
shrink wrap
Packaging and labeling
shock
vibration
humidity
temperature
Standards
specification
test method
verified
validated
Performance testing

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