Container Loading & Palletisation
Work from the carton, not the case. Take carton length, width and height and pieces per carton, build a pallet footprint that divides into 1,200 x 1,000 mm or 1,200 x 800 mm without an overhang, set a stack height within the pallet and product limits, then divide the usable container volume by the pallet volume and check the door height.
Key points
- A 40 mm carton overhang on a pallet can cost a whole column of the container.
- KeXin publishes carton dimensions and pieces-per-carton for sixty-four models.
- Stacking height is limited by the weakest case in the stack, not by the strongest.
- Where a customer orders repeatedly, adjusting the carton by a few millimetres is often worth more than negotiating freight.
The calculation
Where the waste hides
Almost always in the last few millimetres of a carton dimension that prevents a clean grid on the pallet, or in a stack height that stops one layer short of the container limit. Both are fixable at the packing design stage and unfixable afterwards.
Applications
This matters most where the case is part of a movement chain rather than shelf packaging. In military and outdoor & recreation the same shell is specified differently because the handling, the environment and the verification requirement differ.
- Military — Military equipment moves through a chain of handlers, none of whom own the equipment and all of …
- Outdoor & Recreation — Consumer and professional outdoor brands buy cases as a component of their product. That means c…
Customisation
Everything described above is configurable on a standard shell: interior layout (pick-and-pluck, die-cut or CNC-cut), foam grade and thickness, colour, logo method, latch and lock count, pressure-equalisation valve, cable ports, document holder and identification plate. A bespoke exterior geometry requires a new mould — 125 days, from 3,000 units per moulded component.
Procurement considerations
| Question | What to send us |
|---|---|
| Which shell fits? | Equipment L × W × H as packed, plus required clearance per axis |
| What does it cost? | Order quantity and estimated annual quantity — the two drive different answers |
| Is tooling needed? | Whether an existing shell clears the envelope with usable foam depth |
| Lead time? | Your required delivery date, not just the order date |
| Certification? | The exact standard your tender names — we will say whether we can test to it |
| Freight? | Destination and preferred terms; carton and pallet data supplied with the quotation |
Comparison and selection guide
The tables on this page exist because a protective case is chosen by comparing three things: the envelope, the environment and the handling chain. Where no table applies, the rule below is.
| Situation | What To Do |
|---|---|
| Sea freight | Sealed configuration plus desiccant; salt spray is a handling issue, not a material issue. |
| Air freight | Mass and external dimensions drive cost more than volume. |
| Repeated movement | Replaceable latches, hinges and gaskets; keep a spares kit with the first order. |
- Size on internal dimensions plus clearance, never on a product name.
- Choose the carrying method before the shell: it changes the series, not just the price.
- Specify the interior last, and decide up front whether the end user will reconfigure it.
Container Loading & Palletisation relates to Logistics & Packing Guide. Related families: Equipment Transport Cases. Related sectors: Military / Outdoor & Recreation. Continue in the Logistics & Packing Guide cluster.
This page is written from our own production data. If your requirement differs, send the dimensions and we will tell you which of the 155 models fits, or whether a custom route is needed.
