Best Practice Pallet Handling in Challenging Environments
- Disruptive Packaging
- 4 days ago
- 4 min read
By the Design Team, Disruptive Packaging
Handling and packing pallets correctly can make a big difference in how goods travel and how well they're protected during transport and storage, especially when facing tough conditions like sun exposure, time outside of cold-chain, high humidity, and long-distance exporting. Many businesses know how to handle pallets correctly for stability and product safety; however, they don't realise there are differences depending on their packaging and material specifications. Our designers have provided practical tips when working with URTHCOR® and URTHCOOL® to improve your packaging performance and handling.
Why Proper Pallet Handling Matters
Packaging is the backbone of logistics, but poor handling can cause damage, delays, and extra costs. When packaging is exposed to harsh environments, such as high humidity, direct sunlight, or freezing temperatures, the risk of product spoilage or structural failure increases. For example, heat can weaken packaging materials, while cold rooms can cause condensation and moisture damage.
Using the right stacking method and packaging materials helps maintain integrity throughout the supply chain. Businesses that adapt their pallet handling to environmental challenges save money and improve customer satisfaction.
Top Tips
Column Stacking vs. Cross-Stacking
One key decision in pallet packing is how to stack the boxes. Common methods are column stacking and cross-stacking, or a hybrid of both.
Column stacking means placing boxes directly on top of each other in straight columns. This method creates a strong, stable structure that evenly distributes weight.
Cross-stacking involves alternating the direction of boxes in each layer, which can increase airflow.
Hybrid stacking is a combination of both column and cross-stacking. This can mean the top layers differ from the bottom layers, or the outer boxes are column stacked while the inner boxes are cross-stacked.
We recommend column stacking your URTHCOR® boxes over regular cross-stacking for most situations, especially when pallets face environmental stress. Column stacking minimises crush on the bottom of the pallet. Cross-stacking can be useful when the products require careful securing to prevent instability.
Benefits of Column Stacking
Improved stability: Boxes align perfectly, reducing the risk of collapse.
Better weight distribution: The load spreads evenly through the corners of each box.
Easier wrapping and securing: Stretch wrap or strapping holds the pallet firmly.
Reduced damage risk: Less shifting means fewer crushed boxes.
To get the layout right, our team asks the questions: what layer rotation is needed? What are the box heights and weights? This information changes everything.
Where we add value is knowing the specificities of our global customers. For example, U.S. produce demand only a few configurations of down stacking, whereas our U.S. seafood customers have more variables.
Protecting Your Pallets from Sun Exposure
Sunlight can cause several problems for various types of packaging and their contents:
Heat buildup: Direct sun can raise temperatures inside packaging, damaging heat-sensitive products.
UV damage: Prolonged exposure weakens plastic wraps and corrugated plastic boxes, as well as melts wax on wax-impregnated boxes.
Fading and discolouration: Labels and packaging may become unreadable.
Some manufacturers add UV additives to packaging, which provides protection against light degradation, but it comes with several downsides: compromised aesthetics, processing challenges, potential health and food-safety risks through chemical migration, and complications in recycling. We don't incorporate UV additives for those reasons and ensure our packaging doesn't contain unnecessary chemicals.
To protect your URTHCOR® and URTHCOOL® packaging from sun damage, we advise the following:
Use UV-resistant stretch wrap or covers over the boxes.
Store in shaded or covered areas when possible.
Minimise exposure to the sun for extended periods of time.
Handling Your Pallets in Cold Storage
Cold storage environments require special care to prevent moisture buildup and freezing damage:
Use moisture-resistant packaging materials.
Wrap pallets tightly to prevent condensation from reaching products.
Avoid stacking directly on cold floors; use pallets or mats to create a barrier.
Monitor temperature changes during loading and unloading to reduce thermal shock.
Column stacking helps here by keeping the pallet compact and easier to wrap tightly, reducing gaps where moisture can enter.
Combining the above practices with high-performance thermal packaging, URTHCOOL®—specifically engineered for seafood and frozen produce—addresses the strength, thermal, and waterproof requirements in supply chains.
Extra Tips on Packaging Care
Use corner protectors: Corner Angles, also known as Angle Boards, help maintain box shape and improve load stability.
Check the Box Maker's Stamp (BMS) and labels: Manufacturers mark their boxes with clear handling instructions and environmental warnings.
Check pallet quality: Use sturdy pallets without cracks or splinters.
Secure loads with straps or bands: This adds extra support beyond stretch wrap.
Train staff: Proper handling techniques reduce accidents and damage.
Quality Protection with No Compromise
Adapting pallet handling and packaging to environmental conditions is essential for protecting goods and reducing waste. We recommend businesses review their handling and storage processes regularly and adjust for seasonal changes or new storage conditions. Taking these steps helps avoid costly damage and keeps operations running smoothly.
Column stacking offers a strong, stable base that, combined with the right materials and protective measures, ensures goods and products arrive safely and maintain quality.
Ready to get started? Test column stacking on your next pack-out or shipment and observe the difference in stability and protection.
