Plastics Logistics : Core Problems with Non-Conforming Container Loading

The plastics industry faces significant challenges when containers are loaded improperly or with irregular configurations. 

These non-compliant loading practices affect efficiency, safety, and cost throughout the supply chain.

Physical and 0perational issues:

Product damage: 

Irregular loading creates uneven pressure distribution and instability that can:

• Deform plastic pellets in bulk containers
• Crush packaging for finished products
• Create stress points on extruded plastic sheets or rolls

Space utilization inefficiency: 

Non-conforming loads typically:

• Waste 15-30% of available container space
• Create "dead zones" where no product can be safely placed
• Require additional shipping containers for the same volume of goods

Safety hazards: 

• Improper loading directly contributes to:
• Shifting loads during transit (particularly dangerous with heavy resin containers)
• Collapsed stacks in warehouses
• Worker injuries during unloading operations

Real-world examples:

Raw materials transport:

A manufacturer improperly loaded gaylord boxes (large cardboard containers) of plastic resin by:

• Stacking them in a 3-high configuration despite a 2-high specification
• Placing them in a non-uniform pattern with gaps
• Using insufficiently rated boxes for the weight

Result: 

During ocean transit, the movement caused multiple boxes to collapse, spilling approximately 2,000 lbs of plastic pellets throughout the container. This created:

• $14,000 in material losses
• $5,800 in cleaning/recovery costs
• Two-week production delay

Finished product shipping:

PET Bottles: 

• A beverage packaging supplier loaded pallets of empty PET bottles:
• Without properly securing top layers
• With insufficient stretch wrap
• Using pallets of inconsistent dimensions

Result: 

The load shifted during transport, causing bottles to fall between pallets and become crushed. This led to:

• 30% product rejection rate
• Emergency replacement production
• Delayed filling operations for the customer

Distribution center challenges:

Mixed plastics products: 

A distribution center received containers with a wide variety of plastic products:

• Loaded without considering product density differences
• Heavy injection-molded containers placed above lighter items
• No standardized orientation for similar products

Result: 

Unloading time increased by 60%, workplace incidents rose, and order fulfillment was delayed.

Compliance solutions:

Standardized loading patterns: 

Developing product-specific loading diagrams with clear visual guidelines

Training programs: 

Implementing proper training for loading personnel on material properties and stacking limitations

Technology integration: 

Using load planning software and verification systems

Packaging redesign: 

Creating more uniform, interlocking packaging

Loading equipment: 

Investing in specialized equipment like slip sheets and container loading systems

In the plastics industry, where margins are often tight and product damage is costly, addressing non-conforming loading practices represents a significant opportunity for operational improvement and cost reduction.