Product Load Optimisation

This is the Supply Change.™

Shipping more for less.

The opportunity

A small improvement in how much product you can move on a pallet or in a container can lead to significant cost reductions. You can get these savings—savings that lower labour costs, handling costs, distribution platform costs and transport costs—often with no operational change. 
CHEP makes Product Load Optimisation simple. Our process is customised, efficient and cost-effective— especially when you consider that many companies experience an ROI of up to 400% from this initiative. That’s what can happen when product loads are optimised every day, for every load.


Optimised product loads typically reduce:

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What we do

Only CHEP combines the expertise of our experienced engineers, state-of-the-art software and access to testing at accredited testing facilities. CHEP brings together two unique capabilities—product load configuration and packaging testing—in one solution. Together they help you configure maximum load efficiency for every load and test configurations to ensure real-world success.

This can help you move product more economically, reducing fuel and labour costs. It also helps you make the most of your manufacturing and warehouse space. What’s more, Product Load Optimisation helps many customers “find money” in their supply chains. By periodically testing how and what you’re shipping we find new ways and new efficiencies that often result in new savings.

We take into consideration individual packaging dimensions, the total product load weight and the weight capacity of the truck. Each case pack is then placed in the ideal location and direction, building a product load design that can carry the maximum amount of product securely with minimal damage.

Then we’ll make sure everything works in the real world. In testing labs, we’ll simulate distribution hazards associated with handling operations, warehouse stacking, transportation and atmospheric conditions. We’ll also look at the impact of transportation, forklifts, automated systems, manual handling and environmental conditions. Once lab tests are completed, we’ll design and execute field-test programs to ensure everything works as planned. 

Our local test-lab partners are certified by the South African Bureau of Standards. CHEP’s Innovation Center is certified by ISTA, representing manufacturers and packaging suppliers, working together to ensure responsible packaging.

How we’ll improve your product loads together.

How we’ll work together

CHEP couples software analysis of your product loads with exhaustive in-lab and real-world testing. We’ll collaborate with you in designing the optimal product load as well as the right testing to make sure it performs. This collaborative process is your assurance that you’re doing everything to get the most out of your product loads.

Optimising by putting software and testing together:

+ We’ll identify your product load optimisation needs and determine the number of configurations to evaluate

+ We’ll verify the product load metrics important to you, complete all agreed-upon optimisations, then test and analyse all potential optimisations

+ We’ll compile a full test report, with product load diagrams and test data, then review all results with you and determine if additional studies are required


Optimising your product load in four to six weeks: 


How you'll benefit

Product Load Optimisation is one of the simplest ways to realise improvements throughout your supply chain. We can help you:

+ Configure individual case packs in a way that places the greatest possible amount of product onto a pallet or into a container

+ Understand the impact of the supply chain on new products, and on new primary, secondary or transit packaging

+ Reduce distribution platform procurement costs, shipping material costs, transportation costs, labour costs and material handling costs

+ Gain a better understanding of certain conditions that play a role in product damage

+ Get detailed information on the performance of product loads throughout your supply chain on different platforms 

+ Discover the optimal mix of product, packaging and productload transit packaging

+ Optimise both product and trailer loads so you can significantly cut transportation costs and reduce carbon footprint

+ Use more sustainable packaging with less corrugate and shrink wrap. 

+ Optimise space utilisation of manufacturing and warehouse facilities

+ Reduce costs associated with primary packaging, secondary packaging, transit packaging (slip sheets and shrink wrap) and shipping platforms

+ Certify product loads being shipped down your supply chain


Only CHEP offers product load configuration, in-lab packaging testing and real-world performance evaluation in one solution, backed by the experience of CHEP’s engineers and our ISTA-certified Innovation Center. We can simulate and test every impact factor within every leg of your supply chain, to eliminate real-world mistakes. We’ve done this for many of the largest companies around the world. We look forward to working with you as well.

Real-world ROI from Product Load Optimisation.




We showed a South African poultry supplier how switching from cardboard to CHEP RPCs improved their pallet utilisation by 33%.

                                  Current     Proposed

Items per case          12            16

Kgs per case             14.75       19.67

Cases per pallet        50            50

Kgs per pallet            737.5       983

Items per pallet         600          880