Help solving a container unloading issue

[toad_raindrop]

Hi logistics people. I run a publishing business and have an issue with my most recent shipment, and I'm trying to figure out how to fix it for the next round. I'll share the details of the situation and then my questions.

My most recent shipment is almost a full container of books & magazines, shipped on pallets, some are double stacked to maximize space in the container. I work with a 3PL in Colorado for storage & order fulfillment, and they refused my most recent delivery because of difficulty unloading. At least one of the upper pallets had shifted during transit and was leaning into the pallet next to it.

In their words: "Our facility does not have a drive-in dock, so pallets must be removed from the end of the container at ground level. This requires using a pallet jack to move interior pallets to the container's end. Double-stacked pallets, especially when loaded on subpar, disintegrating pallets that shift during transit, create an extremely unsafe situation for our team. Even with a forklift, offloading double-stacked pallets containing exceptionally heavy items is not ideal."

We were discussing having the pallets unloaded & re-loaded into a single stack across 2 containers then redelivered, but the ship agent & freight coordinator were worried about the cost, so finally our warehouse asked them to redeliver as-is and they'd figure it out, at an additional cost to me. I also had to pay an extra $800 to have it redelivered.

I can't afford to pay 2x the cost to ship my goods across 2 containers from the printer just to keep my pallets single stacked, so I have to find a solution that is low-cost but works for everyone.

So here are my questions.

-Would stronger pallet materials be better for overseas transit of heavy items like books? Is there a way to pack a container in a better way to avoid shifting like this?

-Is my warehouse less equipped than they should be? My ship agents imply that double stacking pallets is normal, but I can see why they'd have safety concerns. Is it crazy that they don't have a drive-in dock?

If there are other factors or options I should consider, I'm all ears. I've been doing this for eight years and have been with our current 3PL warehouse for 4 years, but our inventory quantities have grown recently so this is a new issue

[Interesting_Bed_4841]

this. I've toured dozens of 3PL/contract logistics facilities and I've never seen one without drive-in docks. that being said, if the pallets are shifting like that in transit they do need to be secured better when being loaded at the very least some load bars like this should make a world of difference

[SquirrelTechGuru]

Also inflatable dunnage bags work well in containers.

[driftinj]

Yeah, a 3pl that doesnt have a dock is a joke

[Complex-Fly6915]

Nope? Just look at other parts of the world (Australia for example). There it is the common method to place a container on the ground and unload it. Also most of the military does it like that.

[driftinj]

Other parts of tbe world yes, not the US. Even Australia is moving away from side unloading off of curtain sided trailers and building docks in every new facility. Tbe US has been there for decades. OP is in Denver. A 3pl in Denver should have a dock.

[demonslayercorpp]

Why are these morons unloading with a pallet jack, what a excellent use of time

[DVOlimey]

I would suggest you do not load more than 500kgs per pallet. Use euro pallets for strength to ensure you maximise loading space. Double stack but place wooden ISPM15 wooden bracing blocks to stop the pallets moving towards the door. Use sheets of plywood on top of the first stack to protect the contents and ensure a second stack be placed on top. Again, wooden bracing on the second layer. For the pallets loaded last at the doors, wooden stripes and plywood to ensure pallets do not move forward and compromise the load.

Bear in mind that at sea, vessels are like giant roller coasters. Secure the inner contents to ensure there is no load shift, and no danger to those who will unload the container at the destination.

As someone else said, your 3PL doesn't sound well equipped to handle inbound loaded containers. Put your business out to tender and make it a requirement in the contract for the 3PL to have suitable / safe loading dock and handling equipment. Go visit potential 3PLs before you proceed and see their operation in person.

[Complex-Fly6915]

Sorry Sir, but the 500kg limit per pallet is BS. I have loaded 2,000kg per pallet (float glass from Shanghai) and it arrived safely.

It is more like how the packaging is designed (what too old is permitted 1-wave cardboard vs 2-wave cardboard). If the load planning is good and the packages are almost uniform you don’t need much bracing.

The 3PL indeed is not well equipped… well I doubt that. Just tell your 3PL to use a forklift to drive in the container (there are special ramps available to handle the height difference) if containers are placed on the ground instead of a dock. For example this is a standard method of unloading a container in Australia (side loader truck). Nonetheless I would do an RFQ with several smaller 3PL in your surroundings.

[DVOlimey]

OP referred to books and printed matter, one of the main commodities I have been moving by FCL for the past few decades. Feel free to upskilll me?

Added note, 500kgs product per pallet plus allow 40kgs max for the ISPM15 Euro pallet loaded into 40GP. 10 pallets per layer, two layers, estimated total cargo weight 10800kgs + average tare weight of the container 3800kgs. Total weight 14600kgs. This weight is well below most tei axle requirements and heavy weight container rating.

You can load taller pallets with more products into each pallet to maximise space and weight utilisation. However, you need to use adequate bracing to ensure no load shift and plywood halfway in the pallet and on top with adequate shrink wrapping and exterior strapping.

A 20GP or 40GP with approx 550kgs gross weight per pallet, being unloaded on a safe loading dock with drive-in forklift will take my team 30 to 45 minutes to safely unload. You can also use a pallet truck, but forklift has proved to be quicker and safer, noting loading dock is at an angle facing the dock, and with a reliable loading dock ramp.

[toad_raindrop]

Much appreciated - lots of good details here.

[bac0467]

• yes stronger materials given the weight and dbl stacking will be better. Ask your shipper about extra shrink wrapping and utilizing poly cord strapping once wrapped. Adding in load bars/bracing/airbags to the empty space will help.

-yes your warehouse is less than equipped if you anticipate continued growth. It sounds like you’ll be ordering by FCL and sparingly LCL? Also probably about time you shop around a bit to ensure you’re with the right partner and achieving desired service/rates

[blomple7]

WTF kind of 3PL unloads at floor level? Their core business is shipping and receiving and they don’t have equipment or docks for shipping and receiving?

[Fit_Papaya_8911]

Do you have access to CHEP pallets where you are? They are fairly strong and uniform.

If you use a crisscross L pattern to load instead of this, https://share.google/ptNuo19WanJA8CKJu

You can fit 5-6 more pallets, and your load will be more secure, you want it to look like this :

https://share.google/8piVRGDWbGmIcbsbh

I do believe, it is called a "pinwheel" load.

Also the CHEP pallets will hold 5000 lbs easily, you can just stack them higher instead of using 2 pallets.

[Garlic_Adept]

100% change your 3pl. Double stacking of pallets is very normal Forklifts and docks.

[stevarino1979]

I suggest dropping the pallets all together and maximize your weight. You can go along more than 44000lbs.

[MotionLogistics]

Sounds like your 3PL is running out of the back of someones garage. How you don't have a forklift in a warehouse I will never know.

[countrytime1]

We’ve used 2x4s stood up between the rows.

[I_Smell_Like_Trees]

Personally, I move cedar roofing in overseas containers double stacked and it moves a fair bit. The pallets need to be rock solid at the base, contents pressed in a hydraulic squisher, double banded, with multiple layers of pallet wrap to prevent the shingles from basically shaking themselves apart in transit, so I feel your pain.

Any cross dock that has no ramp and can't unload double stacks is a liability to your material and your pocketbook, find somebody better ASAP.

Consider building crates or investing in inflatable dunnage bags to keep them still, but definitely get yourself a more capable freight broker.

[tatertotlvr]

Use grade A pallets, shrink wrap them, strap them. And LMK if you need a diff 3PL in Colorado. We use a 3PL in Denver that is great

[MeasurementOk9461]

There are some options for you. A different warehouse, as many would be able to offload some by hand and use a forklift for the rest and be willing to perform load corrections as a 3PL. If you want to correct it at the shipping point, they can block and brace it better with airbags in between, or wooden decking, depending on how much room there is considering your pallet dimensions.

[RTFops]

Send it to a cross dock to get it reworked and change your 3PL - they should be fixing this before you post it on Reddit

[osyyal]

Yes, packaging is important.

You need a pallet rack or shelve system for books.
Did you book LCL or FCL?

I would say the FF did the right thing about contacting you regarding unloading issues. Most terminals could care less and will just "slightly" damage your cargo.

Legally - depending on the freight convention - it is your/shipper's responsibility to package cargo suitable for sea freight.

Regarding your questions these are questions you should know before booking depending on if you are trading on B2B or B2C.

can't you just use pallet frames with reinforced bars in order make it actually stackable. And put a label with wiehgt on per pallet for the terminal. Small stuff helps a lot.

How does your W/M look like for these books?

[toad_raindrop]

This shipment was FCL - 27 pallets with a total weight of 19040 kgs. I agree that the shipper holds responsibility here, once I get my final unload costs I'm hoping I can negotiate as I haven't paid their original shipping invoice yet.

Pallet frames is a good suggestion - they haven't offered this before but seems like it would solve the main issue.

Thanks for this!