All Member Forum

How have you balanced reducing material costs and improving pallet efficiency while still ensuring that your brown boxes meet critical strength and durability throughout distribution? 

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Jacob Sachs CPP
Mars Wrigley Global
Chicago IL
NA
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Hi Jacob,

First you have to analyze how the current pallet load is being stacked and identify possible weak points. Does the product inside provide any rigid structural strength (ie. bottles, boxes, jars, etc.) and if so, can the headspace in the shipper be eliminated? Column stacking the first few layers on the pallet and then interlocking the higher layers can provide corner to corner strength to the lower layers. Then determine if downgrading the board would suffice after testing. Sometimes changing the pack configuration inside while maintaining the piece count can allow a more efficient pallet load. There are a lot of variables to consider.

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John Hwang, CPP
Owner
Packaging Solutions Consulting, Inc.
Chino, CA
(626) 688-4112
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Hi John,

Is there any data available comparing pallet stack strength between interlock stacking, column stacking, and a hybrid one (column stacked on the bottom with interlocked layers above)?

Thanks.

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Rashid Nehal CPP
Packaging Professional
Brampton ON
6472974681
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Original Message:
Sent: 04-29-2025 05:17 PM
From: John Hwang
Subject: Brown Box Strength and Pallet Efficiency

Hi Jacob,

First you have to analyze how the current pallet load is being stacked and identify possible weak points. Does the product inside provide any rigid structural strength (ie. bottles, boxes, jars, etc.) and if so, can the headspace in the shipper be eliminated? Column stacking the first few layers on the pallet and then interlocking the higher layers can provide corner to corner strength to the lower layers. Then determine if downgrading the board would suffice after testing. Sometimes changing the pack configuration inside while maintaining the piece count can allow a more efficient pallet load. There are a lot of variables to consider.

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John Hwang, CPP
Owner
Packaging Solutions Consulting, Inc.
Chino, CA
(626) 688-4112
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Hi Rashid,

The Fiberbox Handbook has a good break down of estimated compression loss based on varied pallet patterns (i.e. interlocking vs column stack). I do not recall if there is a calculation for the hybrid scenario, but traditionally that is commonly what we recommend to maintain strength AND load stability by interlocking one or more of the top layers.

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Rob Kaszubowski CPP
Director, Packaging Optimization
NTT Data - Packaging Optimization (formerly Chainalytics)
Minneapolis MN
(763) 772-2455
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Original Message:
Sent: 07-03-2025 09:33 PM
From: Rashid Nehal
Subject: Brown Box Strength and Pallet Efficiency

Hi John,

Is there any data available comparing pallet stack strength between interlock stacking, column stacking, and a hybrid one (column stacked on the bottom with interlocked layers above)?

Thanks.

------------------------------
Rashid Nehal CPP
Packaging Professional
Brampton ON
6472974681
------------------------------


Original Message:
Sent: 04-29-2025 05:17 PM
From: John Hwang
Subject: Brown Box Strength and Pallet Efficiency

Hi Jacob,

First you have to analyze how the current pallet load is being stacked and identify possible weak points. Does the product inside provide any rigid structural strength (ie. bottles, boxes, jars, etc.) and if so, can the headspace in the shipper be eliminated? Column stacking the first few layers on the pallet and then interlocking the higher layers can provide corner to corner strength to the lower layers. Then determine if downgrading the board would suffice after testing. Sometimes changing the pack configuration inside while maintaining the piece count can allow a more efficient pallet load. There are a lot of variables to consider.

------------------------------
John Hwang, CPP
Owner
Packaging Solutions Consulting, Inc.
Chino, CA
(626) 688-4112

Hi Jacob,

One effective solution is using HDPE pallets, which are lightweight, sustainable, and recyclable. These pallets are easy to carry, reducing logistical costs while being environmentally friendly.

For the packaging itself, the choice of carton strength and design plays a key role. Depending on the product, we can opt for ready-for-shelf cartons, which are sturdy and presentable, or choose a lesser ply carton that balances cost-efficiency with strength. The key is to ensure that the selected material can withstand the rigors of transportation and storage while reducing excess material use.

Ultimately, it's about finding the right balance between durability, cost-effectiveness, and sustainability. With a number of factors and parameters one can carefully select materials and optimize pallet designs, to meet both cost and performance requirements without compromising on the integrity of the packaging.

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Nikhat Sayed
Printing & Packaging Engineer
Irvine CA
(714) 548-4383
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In my opinion, firstly ensure the corrugated box has design without leaving too much headspace (this will reduce box compression strength). Then calc. the required compression strength by multiply box load X staking layers X safety factor (this largely depends on distribution route intensity). Next, use Mc Kee or Kellicut Formula to predict corrugated material combination that could provide required compression strength.
Also, column stacking is preferred to minimize the carton stacking strength deterioration throughout distribution cycles.

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Han Woei Tan CPP
Product Development Engineer - Packaging Design
Fisher & Paykel Appliances Dunedin
B.M
+60184667899
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You can explore cheaper board combination options that still provide you with the strength and durability required.  The corrugated industry is constantly enhancing the performance of their liners with high performance liners that are lighter but more durable than heavier liners.  Gapping the flaps is always a favorite when looking for cost savings while not really giving up performance.  Some companies have made huge strides when going from something like B flute to a half step down to E flute by going to the in between D flute.  You might also be able to take advantage of the "deeper is cheaper" concept, if you currently have a box where the largest dimension is NOT the depth, you can change the orientation of the box so that the depth is the largest dimension -this reduces the size of the flaps which reduces the size of the blank, which reduces the cost of the box, typically.  Another strategy is to use a cost-effective design, for instance, an RSC is generally much more cost effective than an auto-bottom.  If you are using 100% virgin or 100% recycled board, those are typically more expensive than corrugated board that is composed of a mix of virgin and recycled material.         

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Andrew Dee PMP
Adept Group (Adept Packaging)
Snohomish WA
(425) 293-5294
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Original Message:
Sent: 05-21-2025 04:59 PM
From: Han Woei Tan
Subject: Brown Box Strength and Pallet Efficiency

In my opinion, firstly ensure the corrugated box has design without leaving too much headspace (this will reduce box compression strength). Then calc. the required compression strength by multiply box load X staking layers X safety factor (this largely depends on distribution route intensity). Next, use Mc Kee or Kellicut Formula to predict corrugated material combination that could provide required compression strength.
Also, column stacking is preferred to minimize the carton stacking strength deterioration throughout distribution cycles.

------------------------------
Han Woei Tan CPP
Product Development Engineer - Packaging Design
Fisher & Paykel Appliances Dunedin
B.M
+60184667899
------------------------------

Hi, a couple more things to evaluate- Consider atmosphere in which products are being transported and stored and for how much time. Corrugated Box strength can't be reduced to below certain number (ECT or Bursting) So use factor of safety say 3 times if weight of the box or as required. Secondly compression strength can be evaluated using Tops Pro software so compare various material grades and analyze the performance. Also apart from the calculated strength, I'd rely more on actual ship test and observe the performance!  

 

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Devdatta Chitale
Atkore Inc
Delaware OH
(585) 363-8877
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Original Message:
Sent: 05-22-2025 05:48 PM
From: Andrew Dee
Subject: Brown Box Strength and Pallet Efficiency

You can explore cheaper board combination options that still provide you with the strength and durability required.  The corrugated industry is constantly enhancing the performance of their liners with high performance liners that are lighter but more durable than heavier liners.  Gapping the flaps is always a favorite when looking for cost savings while not really giving up performance.  Some companies have made huge strides when going from something like B flute to a half step down to E flute by going to the in between D flute.  You might also be able to take advantage of the "deeper is cheaper" concept, if you currently have a box where the largest dimension is NOT the depth, you can change the orientation of the box so that the depth is the largest dimension -this reduces the size of the flaps which reduces the size of the blank, which reduces the cost of the box, typically.  Another strategy is to use a cost-effective design, for instance, an RSC is generally much more cost effective than an auto-bottom.  If you are using 100% virgin or 100% recycled board, those are typically more expensive than corrugated board that is composed of a mix of virgin and recycled material.         

------------------------------
Andrew Dee PMP
Adept Group (Adept Packaging)
Snohomish WA
(425) 293-5294
------------------------------


Original Message:
Sent: 05-21-2025 04:59 PM
From: Han Woei Tan
Subject: Brown Box Strength and Pallet Efficiency

In my opinion, firstly ensure the corrugated box has design without leaving too much headspace (this will reduce box compression strength). Then calc. the required compression strength by multiply box load X staking layers X safety factor (this largely depends on distribution route intensity). Next, use Mc Kee or Kellicut Formula to predict corrugated material combination that could provide required compression strength.
Also, column stacking is preferred to minimize the carton stacking strength deterioration throughout distribution cycles.

------------------------------
Han Woei Tan CPP
Product Development Engineer - Packaging Design
Fisher & Paykel Appliances Dunedin
B.M
+60184667899