The Tetris of shipping: Container stuffing explained

Container stuffing is beyond simply loading goods into a shipping container.

A critical process in the logistics industry, this procedure may seem straightforward at first. But, it requires meticulous planning for optimal space utilisation and safe transportation. Here’s everything you need to know as a shipper about container stuffing.

What is container stuffing?

Container stuffing involves carefully placing and securing cargo within a container before it gets transported by sea, rail, or road.

Imagine container stuffing as a Tetris-like challenge, where companies have to fit various shaped and sized cargo pieces together in a container.

Not all goods are stuffed the same way

Differences in cargo nature and packaging lead to variations in container stuffing methods. For example, are the goods in pallets or big bags? Are they fragile, perishable, or hazardous? This will determine the specific handling and stuffing techniques required to prevent damage. Additionally, it ensures compliance with international shipping regulations.

The process takes into account the nature of the goods, their weight, the container's dimensions, and the destination requirements to optimise the load. It's not simply about fitting items into a space but doing so in a way that ensures their integrity upon arrival.

FCL vs. LCL container stuffing

Full container load (FCL) stuffing involves filling a container to its optimal capacity with goods from a single consignee, while less-than-container-load (LCL) stuffing involves consolidating cargo from multiple consignees into a single container.

Container stuffing vs. container filling

Container filling refers to putting cargo into a container with the goal of reaching a specific volume or weight. It doesn’t necessarily consider factors like safe weight distribution, securing cargo to prevent damage, or maximising space utilisation.

On the other hand, container stuffing is a more comprehensive process that considers these additional factors. It’s about strategically loading the container to achieve several goals, including safety, efficiency, and compliance.

So, while filling a container might just involve throwing boxes in until it’s full, proper container stuffing involves planning, technique, and careful execution.

Why do you need to optimise container stuffing?

• Cost reduction: By maximising the container space, you can fit more cargo, reducing the number of containers needed for shipment. This translates to lower shipping costs.
• Safe transportation: Improperly loaded containers can be safety hazards. And uneven weight distribution can cause the container to tip or become unstable, potentially harming dockworkers, crew, and the cargo itself.
• Reduced damage: Proper weight distribution and securing cargo prevents freight from shifting around during transport. This reduces the risk of damage to your goods.
• Maximised space: Proper stuffing optimises container space, reducing shipping, handling, and labour costs per unit. This benefits both the shipper and the recipient.
• Regulatory compliance: Containers have weight restrictions to ensure safe transport. Optimising stuffing ensures you stay within these limits and avoid penalties.
• Environmental impact: Filling containers to adequate capacity reduces the number of trips needed, lowering fuel consumption and emissions.

Environmental impact: Filling containers to adequate capacity reduces the number of trips needed, lowering fuel consumption and emissions.

Plan the puzzle: Step-by-step process of container stuffing

1. Preparation for stuffing

   • Container selection: The right container type (dry, reefer, etc.), size (20ft, 40ft, etc.), and quality are chosen based on the cargo type, weight, and volume.
   • Inspection: The container’s interior is inspected for cleanliness, damage, and proper functioning (refrigeration units for reefers).
   • Documentation: Necessary paperwork like packing lists and commercial invoices are prepared for customs clearance.

2. Cargo preparation

   • Palletisation: Where possible, cargo is placed on pallets for easier handling and stacking within the container.
   • Packing and securing: Individual items are packed securely using appropriate materials, like boxes, bubble wrap, and strapping, to prevent damage during transport.

3. Stuffing process

   • Loading sequence: Load heavier items first at the bottom for a stable centre of gravity, preventing tipping. Distribute weight evenly throughout the base for optimal stability.
   • Cargo placement: Follow a load plan to strategically place freight and maximise space utilisation. Start with the heaviest boxes at the bottom, moving to lighter ones as you stack up. Place larger, irregularly shaped items strategically, and use them as a base for stacking more uniform boxes. Ensure to balance the weight both horizontally and vertically.
   • Securing cargo: Dunnage (airbags, wood) fills gaps and prevents cargo from shifting. Straps are applied to secure pallets and individual items to the container walls and floor.

4. Efficiency and planning

   • Time management: Skilled container stuffing crews can load containers quickly and efficiently, reducing container turnaround times and keeping shipments on schedule.
   • Effective communication: Clear communication of plans between shippers, packers, and logistics providers ensures a smooth stuffing process.
   • The right tools: Using the appropriate tools, such as forklifts, pallet jacks, and specialised lifting equipment, streamlines the container loading process.

5. Documentation and sealing

   • Verification: The stuffing crew verifies that all cargo listed is loaded and properly secured.
   • Sealing: The container is sealed with a tamper-evident seal for security and customs purposes.
   • Documentation: The final weight is documented, and all necessary paperwork is attached to the container for transport.

By focusing on these critical aspects of container stuffing, you can ensure safe and cost-effective freight transportation.

Stuffing tips: Maximising space and minimising damage

• Palletise your cargo: Whenever possible, place cargo on pallets for easier handling and stacking within the container.
• Label your freight accurately: Clearly label all boxes and packages with their contents and handling instructions.
• Handle fragile items separately: Fragile items require extra care. Use cushioning materials and special crating when necessary. Keep fragile items away from the container's doors to protect them from shocks during opening.
• Ship dangerous goods carefully: Know the rules! Shipping hazardous materials has specific regulatory requirements. Use trained personnel to handle and secure this freight.
• Leverage tools and technology: Create load plans to visualise cargo placement and optimise space usage. Or you can also use 3D container packing software to virtually test different stuffing configurations.
• Don’t overload: Follow weight restrictions when stuffing to ensure safe transportation and avoid delays or penalties.

Unloading the containers: De-stuffing

The counterpart to container stuffing is de-stuffing, the process of unloading goods from a container. This stage is crucial for maintaining the integrity of the cargo and ensuring it reaches its destination in the best possible condition.

Stuffing services

At Maersk, we ensure optimised container stuffing and destuffing of various types of cargo — whether it’s dry bulk, commodities in big bags, or palletised goods. We also offer services for over-dimension and outsized cargo.

We also offer a range of value-added services in-house for all your container requirements. Explore Maersk Depot Services.