The complexities of liquids in logistics

Out of the estimated 750 million palletised goods that are transported in the UK each year, approximately 11% arrive at the destination having sustained damage. Unfortunately, in the world of logistics and transportation, there are few challenges as intricate and demanding as the movement of palletised liquids.

Here, Rick Sellars Technical Director at Lindum, the UK’s leading expert on pallet stability and packaging, discusses how liquids can add an extra layer of complexity in logistics, and how careful planning, the right equipment, and an understanding of regulatory compliance can help.

When it comes to transporting goods for supply chain management, pallets play a vital role in ensuring the safe, and efficient movement of goods around the world. Improper stacking and wrapping techniques can result in movement in transport (MIT) issues which can cost thousands to rectify.

Recent statistics show that 68% of goods transported worldwide each year are liquids, including beverages and even chemicals. Unfortunately, liquids remain one of the most challenging substances to transport for several reasons. The first reason why liquids can be challenging is the overall weight. Liquids are one of the heaviest goods to transport and often the containers, particularly in chemicals such as paint make them notoriously difficult to transport.

Ultimately, this means they can be difficult to load into a single pallet, and transport vehicles also have weight limits which when exceeded can result in legal issues, damage to infrastructure, and even safety concerns. When transporting liquids, you must consider pallet stacking techniques suitable for the type of product being palletised, paying special attention to weight, shape, and overall size. This will help you to determine a suitable stacking formation.

Using the correct stacking formation will not only help you to maximise space, but also ensure safety, stability, and overall cost-effectiveness. Typically, block stacking is the most common method used in formation, and involves liquid containers being stacked directly on top of each other. While this method can provide maximum space utilisation and stability, it is only suitable for containers that can withstand weight without deformation.

For more fragile or unstable packaging, I would recommend utilising pyramid stacking, or interlocking stacking methods which help to spread the weight more evenly helping to retain product integrity.

Another challenge presented in the palletisation of liquids is movement in transport. Now, overall pallet stability is a concern for any palletised goods being transported, but especially for liquids that can easily spill with any damage to the container.

Unfortunately, pallets that show any signs of damage or leakage are often not accepted by warehouses or retailers, meaning the pallets are sent back. Ultimately this leads to unforeseen costs for the manufacturer each time a pallet is returned.  Besides cost, uncontrolled movement can pose safety hazards for both personnel, transportation, and other road users. Unsecured cargo can cause liquids to spill and, in some scenarios cargo to fall from the vehicle, resulting in accidents and injuries.

In addition, unstable packages and subsequent liquid spillage can pose a serious health and safety threat, especially for chemicals that can cause damage to the vehicle, environment, and personnel. We recently worked with a paint manufacturer who were struggling to transport 10L plastic tubs of paint without the tubs splitting or lids coming off in transit causing spillage. Unfortunately, this led to goods being rejected.

To help mitigate pallet stability issues, take a closer look at the materials you are using to secure your goods. Start by selecting an appropriate pallet that is designed to withstand the weight and dimensions of your containers. Plastic pallets are suitable for packages up to 1,500 pounds. For anything heavier, it is recommended that you opt for a wooden pallet. 

Finally, consider your wrapping material. Most pallet wrap is made from linear low-density polyethylene (LLDPE), which comes in several varieties depending on the characteristics of the package. Heavier, more fragile packages such as liquids may be better suited to heavy-duty NANO stretch film which will help ensure integrity. 

For the paint company, we replicated the exact packing methods used to identify any stability issues using a EUMOS deacceleration test to determine issues. The team then identified a more suitable formation and layer sheets to help protect the packaging. The new pattern increased pallet utilisation from 480L per pallet to 560L per pallet and proved to be highly effective against a G-Force of 0.5g. 

Another thing to consider when transporting liquids is regulatory requirements. Ultimately, liquids can come with a range of regulatory requirements that can dictate everything from documentation to safety measures during transit. Failure to comply can result in pallet rejection, fines, and even legal consequences.

Ultimately, considering each of these issues before palletising your goods will give you peace of mind, knowing your goods are as stable as possible. Whilst road transportation is efficient, it isn’t always the smoothest environment, particularly for fragile goods and liquids. Pallet stability mitigates the chances of damage during transit and can save manufacturers money, and headaches of goods being rejected and the cost of subsequent replacement.

At Lindum Packaging, we understand the complexities of transporting goods and have a dedicated Innovation Centre, and a unique mobile pallet stability test lab  solution to help identify and solve any pallet stability issues for businesses around the country.

Both facilities replicate a company’s current packing process and simulate real-world transportation to identify any weaknesses, which in turn allows us to advise on necessary adjustments for more stable pallets, and cost-effective, sustainable logistics. 

We estimate that the UK could save over 41 million kgs of plastic stretch film each year just by using suitable pallet wrapping. In addition, with UK inflation the price of plastic is steadily decreasing meaning many companies are saving a substantial amount in logistics. 

While liquid products can be notoriously complex to palletise, careful planning can help solve movement in transport issues, improve overall safety, reduce cost, and even lower carbon emissions as we look toward a more sustainable future.  

https://www.lindumpackaging.com/