Why Loads Fail in Transit (and the Cheap Fixes That Prevent It)

Freight damage is one of those costs that gets absorbed quietly until it shows up in a customer complaint, a chargeback, or a rejected delivery. Most of it is preventable. The frustrating part is that most of it comes from the same small set of mistakes, and most of those mistakes are cheap to fix.

The most common causes of load failure

Overhang

Load extends past the pallet edge. Overhanging weight is unsupported, putting stress on corner cartons and increasing the risk of shifting in transit.

Fix: keep overhang under one inch on any side. Match the pallet footprint to the load.

Underfill

Gaps between cartons and open space inside a stretch-wrapped load allow movement. Cartons lean, corner boards lose their function, and the load becomes unstable.

Fix: fill void space with dunnage, corrugated pads, or foam. Cheaper than one damaged shipment.

Loose stretch wrap

Minimal passes and loose film make the load look wrapped without actually securing it. Film without tension has a fraction of the holding strength of properly applied film.

Fix: 4-5 passes minimum, consistent tension, lock to pallet base on the first pass.

Overloaded pallets

Dynamic weight ratings are typically 60-70% of static ratings. A pallet rated 2,500 lbs. static may only handle 1,500 lbs. in transit.

Fix: check the dynamic rating, not just the static one. More on pallet weight ratings.

Overhang

When the load extends past the edge of the pallet, the overhanging weight is unsupported. In transit, that means flex, compression damage to corner cartons, and increased risk of the whole load shifting. The general rule is no more than one inch of overhang on any side. Beyond that, you're loading the edge of the pallet with weight it wasn't designed to carry.

If your cartons consistently overhang a 48x40, it's worth asking whether a 42x42 or a custom size makes more sense. More on preventing transit damage.

Underfill

The opposite problem is a load that doesn't fill the pallet footprint. Gaps between cartons and open space inside a stretch-wrapped load allow movement. Cartons can lean, corner boards won't do their job, and the load won't be stable during braking or cornering.

The fix is dunnage, corrugated pads, or foam to fill the void. It's cheaper than one damaged shipment.

Stretch wrap technique

Stretch film works when it's applied with tension and overlapping passes. A quick wrap job with minimal passes and loose film is not securing anything. It's just making the load look wrapped.

✓

The basics: Start from the bottom, lock the film to the pallet base on the first pass, maintain consistent tension, and do at least 4-5 passes on standard loads. Film that isn't pre-stretched or applied with tension has a fraction of the holding strength of properly applied film.

Corner boards

Corner boards do two things: they protect the corners of cartons from strap pressure and impact, and they add column strength to the load, which matters under stack pressure. On loads that get stacked or travel in crowded trailers, corner boards are cheap insurance. When do you need corner boards?

Cost in perspective: A full set of corner boards on a standard pallet costs under $5. The carton damage they prevent on a single shipment is usually worth more than that.

Overloaded pallets

Every pallet has a weight rating, and it matters. But the dynamic rating, what the pallet can handle while moving, is lower than the static rating, what it can handle sitting still. A pallet rated for 2,500 pounds static may only be rated for 1,500 in transit.

If your pallet is at or near its rated capacity and you're seeing failures, check whether you're using the right rating for your application. How much weight can a pallet really handle?

Putting it together

None of these fixes are expensive. A wider pallet, a few extra passes of stretch film, corner boards, and dunnage for void fill add very little cost per shipment. Compared to one freight claim, one rejected delivery, or one lost customer, they're well worth it.

Atlas carries pallets in a range of sizes and grades, corner boards, stretch film, and dunnage. If you want to walk through your current setup, we can help figure out what's causing the failures.

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