Logistics decision guide
Floor loading may increase carton count, but handling time and damage exposure can rise. Pallets consume space while making forklift handling, counting and storage much easier.
Without pallet height and deck-edge clearance, more cartons may fit. Each carton must be handled, however, so loading and unloading take longer and packaging strength matters more.
Pallet units move, count and store quickly. The trade-off is pallet volume and weight, no-overhang rules and stack limits that reduce carton capacity.
Ocean freight alone can make floor loading look cheaper. Add origin and destination labor, waiting time, damage, repacking, pallet purchase and recovery.
It depends on the standard and build. Include deck area, pallet height and clearance needed to avoid overhang.
Overhang raises compression and impact risk and may be rejected by a warehouse. Avoid it unless the receiving operation explicitly approves it.
Calculate each SKU separately, then review layer patterns, total height, weight distribution and center of gravity for the mixed pallet.
Enter pallet and carton dimensions plus height and weight limits to compare orientations and required pallets.
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