Elastic Pallet Wrapping for Compressed Unit Load Efficiency

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Solution Overview

Problem

The challenge is to increase the efficiency of shipping by fitting more product per pallet and/or per truckload without reducing the size of rolls or packs and without exceeding the allowable overhang beyond standard pallet dimensions, while avoiding product damage.

Innovation Solution

A method involving a pallet, a stack of packages, and an elastically deformable substrate that secures the stack to the pallet, compressing the stack dimensions to fit within standard pallet dimensions and allowing for efficient loading and unloading into vehicles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the stack dimensions are increased to fit more product per pallet, then shipping efficiency is improved, but the stack exceeds the allowable overhang beyond standard pallet dimensions

Engineering Contradiction:

Improveshipping efficiencyVSAvoidstack length

Core Design Contradiction:

ProductivityVSLength of stationary object

Solution Approach 1:

The stack is compressed to reduced dimensions before being placed on the pallet. This preliminary compression action allows the stack to fit within standard pallet dimensions while maintaining the ability to expand to full product dimensions upon removal of the containment structure, thereby improving shipping efficiency without exceeding allowable overhang.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The physical state of the stack is changed from uncompressed to compressed dimensions. By altering the dimensional parameters of the stack through compression, the system enables more stacks to be accommodated on a single pallet while staying within standard pallet boundaries, thus resolving the contradiction between shipping efficiency and dimensional constraints.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the stack is compressed to fit within standard pallet dimensions, then shipping efficiency is improved, but product damage may occur

Engineering Contradiction:

Improveshipping efficiencyVSAvoidproduct damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The elastically deformable substrate acts as a cushioning mechanism that applies controlled compression force to the stack. This beforehand cushioning protects the product during compression by distributing the force evenly and preventing concentrated stress points that could cause damage, while still achieving the necessary dimension reduction for efficient shipping.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The elastically deformable substrate functions as a flexible containment structure that wraps around the stack. This flexible shell applies uniform compressive force while allowing the stack to expand back to its original dimensions upon removal, protecting the product from damage during the compression and shipping process.

Inventive Principle:

Principle #30Flexible shells and thin films

3Quantity of substance

If larger rolls and packs are used to meet customer desires, then product quality is improved, but fewer packs can be placed on a given pallet dimension

Engineering Contradiction:

Improveproduct sizeVSAvoidpacks per pallet

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The stack containing larger rolls and packs is compressed to reduced dimensions before pallet placement. This preliminary compression allows larger individual product units to be accommodated on standard pallets by temporarily reducing their footprint, thereby maintaining both product quality and shipping efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system transitions the stack from a static uncompressed state to a dynamic compressed state for shipping, then back to the original state upon removal of the containment structure. This dynamic dimensional change enables larger product units to fit on standard pallets during transport while maintaining their full size and quality for customer use.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enhances shipping efficiency by increasing the number of products per pallet and truckload without damaging the products, while maintaining product integrity and usability.

Implementation Method 1

wrapping the stack with an elastically deformable substrate under an applied force to secure the stack to the pallet, thereby forming a unit load

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20250376286A1Methods for improving unit load efficiency

Publication Date: 2025.12.11 PROCTER & GAMBLE CO

AI summary

A method for increasing unit load efficiency may include providing a pallet, forming a stack on the pallet, and wrapping the stack with an elastically deformable substrate under an applied force to reduce one or more of an initial maximum stack length to a compressed maximum stack length or an initial maximum stack width to a compressed maximum stack width. Upon compression the compressed maximum stack length may be from about 1% to about 10% greater than the pallet length, and the compressed maximum stack width may be from about 1% to about 15% greater than the pallet width.