Why Load Securement Matters
A perfectly built pallet is only as good as the load secured to it. Product damage during transportation and warehousing frequently results not from pallet failure but from inadequate load securement — products shift, topple, or separate from the pallet during handling and transit. The Grocery Manufacturers Association estimates that supply chain damage costs the consumer packaged goods industry over $15 billion annually, and improper load securement is a leading contributor.
Beyond product damage, insecure pallet loads create serious safety hazards. A shifting load on a forklift can cause tip-overs. Products falling from unstable stacks in warehouses cause injuries. And unsecured loads in transit violate Department of Transportation (DOT) regulations and can cause accidents on public roadways. Federal Motor Carrier Safety Regulations (49 CFR Part 393) require that all cargo, including palletized loads, be secured to prevent shifting, falling, or leaking during transportation.
Load Securement Fundamentals
Effective load securement addresses three types of forces that act on pallet loads during handling and transit:
- Horizontal forces: During braking, acceleration, and turning in transit, horizontal forces try to slide the load off the pallet. Securement must resist forces of at least 0.8g forward (braking), 0.5g rearward (acceleration), and 0.5g laterally (turning) per DOT requirements.
- Vertical forces: During transit over bumps, potholes, and railroad crossings, upward forces can lift products off the pallet. Securement must resist upward forces of at least 0.2g.
- Compression forces: When pallet loads are stacked, the bottom load must withstand the weight of loads above it without crushing or deforming.
The securement system must work in conjunction with the pallet design. A heavy load on a weak pallet will fail regardless of how well the load is wrapped or strapped. Similarly, a strong pallet under a poorly secured load still results in damage. The pallet and securement system must be designed as an integrated unit.
Stretch Wrap Application
Stretch wrap (stretch film) is the most common load securement method, used on approximately 80% of palletized loads in North America. Proper stretch wrap application involves several key practices:
Film Selection
Stretch film is available in various gauges (thicknesses), widths, and formulations. Standard hand-applied film is 70-80 gauge; machine-applied film is typically 60-80 gauge but is stretched further during application, providing equivalent or better containment at lower material cost. Higher-gauge or higher-performance films are needed for heavy, irregular, or sharp-edged loads.
Application Technique
- Anchor the film: Start by wrapping the film around the base of the load and the pallet itself. This critical step locks the load to the pallet — without it, the load can slide off even though it is wrapped tightly as a unit.
- Apply bottom-up: Wrap from the bottom up with 50% overlap between layers. This ensures complete coverage and consistent containment force.
- Maintain consistent tension: Even tension throughout the wrap provides uniform containment. Too loose and the load can shift; too tight and products can be crushed or film can break.
- Minimum wraps: Apply a minimum of 3-5 wraps around the pallet base, body, and top. Heavy or unstable loads may require additional wraps or higher-performance film.
- Top cap: For loads that do not extend to the top of a stacking level, apply a top cap (a flat sheet of film over the top of the load) before wrapping to prevent products from lifting out of the wrap.
Strapping and Banding
For heavier loads or applications where stretch wrap alone is insufficient, strapping (banding) provides additional securement:
- Steel strapping: The strongest option, used for extremely heavy loads (5,000+ pounds) and industrial products like lumber, metals, and machinery. Steel strapping can apply hundreds of pounds of tension and resists cutting and abrasion.
- Polypropylene (PP) strapping: The most common strapping for general palletized loads. PP strapping is lightweight, affordable, and adequate for most pallet loads up to 2,000-3,000 pounds. It can be applied manually or with automated strapping machines.
- Polyester (PET) strapping: Provides higher tension retention than PP and is used for heavier loads where steel is not required. PET strapping is popular for export shipments where it provides strong securement without the sharp edges of steel.
When using strapping, always use edge protectors (corner boards) to prevent the strapping from cutting into product packaging and to distribute the strapping force across a wider area.
Corner Boards and Edge Protectors
Corner boards (also called edge protectors or angle boards) serve multiple functions: they protect product corners from damage during handling and transit, distribute strapping force to prevent product indentation, provide vertical stacking strength when loads are stacked, and create a more uniform load shape that improves stability. For palletized loads that will be stacked, corner boards are strongly recommended and often required by major retailers and distribution centers.
Testing and Validation
Load securement should be validated through testing, particularly for new product configurations or shipping lanes. ISTA (International Safe Transit Association) test protocols simulate the forces experienced during transportation and can identify securement inadequacies before products ship. Common tests include incline/tip testing for stability, vibration testing for transit simulation, and compression testing for stacking.
In-field observation is also valuable. Periodically inspect loads at receiving to assess how well your securement performed during actual transit. Document issues and adjust securement specifications based on real-world results.
Building Your Securement Program
Effective load securement is a process, not a one-time decision. Develop standard operating procedures for each product configuration, train employees on proper securement techniques, audit compliance regularly, and continuously improve based on damage data and customer feedback.
Pallet Union provides members with load securement guides, training resources, and connections to packaging engineers who can help optimize your securement systems for maximum protection at minimum cost.