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Less-than-truckload (LTL) shipping is a cost-effective way to move products, but it often results in product damage. Unlike full truckload (FTL) shipping, where products stay on the same trailer from pickup to delivery, LTL shipments are handled multiple times at different locations. Each time a pallet is moved, stacked, or transferred, the likelihood of damage increases.
Our packaging engineers work with companies to prevent shipping damage and keep products secure during transit. We’ll explain why LTL shipments experience more damage and the best practices for reducing risk.
LTL shipments don’t go directly from point A to point B. Instead, they make several stops at terminals, where they are unloaded, sorted, and reloaded onto different trucks. With each transfer, the risk of mishandling, dropping, or improper stacking increases.
Because LTL loads combine shipments from multiple shippers, it's difficult to predict what will be loaded next to yours. Without proper protection, your pallet could be crushed or tipped over by heavier or irregularly shaped freight. In contrast, full truckload shipments from one shipper offer more control over how freight is stacked and secured. However, according to a survey conducted by Flock Freight, in 2023, 43% of truckloads were only partially filled, with an average of 29 linear feet of unused deck space. This leads to more freight movement and a higher risk of damage, so it is important to make sure your pallets are stable and well-protected.
Minimizing damage during LTL shipments starts before a truck hits the road. Because LTL freight is handled multiple times throughout its journey, it’s essential to take proactive steps to protect products.
Pallet Optimization
Proper palletizing is the first and most important line of defense against freight damage. Start by using high-quality, undamaged pallets that can support the weight of the load. It is best to avoid overhanging items that could be struck while moving the pallet.
Load optimization is critical in maximizing space and minimizing damage during LTL shipments. An optimized stacking pattern creates more stable and space-efficient pallets, reducing the chance of tipping and damage. When pallet space is used efficiently, shipments are less likely to shift, lean, or collapse under the weight of other freight. Our team of packaging engineers can analyze your current pallet and recommend the best pattern stack that lowers transportation costs and decreases errors in the loading process.
Choose Proper Packaging
Securing the load with stretch film is one of the best ways to keep your pallet stable and to prevent shifting during transit. Starting at the bottom, create a strong base by securing the film to the pallet, then wrapping 3-5 times. Next, wrap your load in an upward direction, overlapping each layer of film by 50% while applying consistent coverage. For greater strength, the film can be applied around the pallet another time.
Using a stretch wrap machine offers greater consistency, efficiency, and load stability, especially for companies with high shipping volume. Stretch wrappers also provide more uniform tension, better load containment, time savings, and reduce material waste. Our team can perform a load containment test to ensure you use the correct gauge film and optimize your stretch wrapper for your specific pallet to eliminate inconsistencies, prevent load failure, and reduce film usage.
Strapping can also be used for additional reinforcement for heavy or top-heavy pallets. Strapping should be tight enough to secure the load without damaging the boxes or items being shipped. Strapping protectors and corner board can be used as additional security to prevent strapping from cutting into the package or product, especially for fragile or irregularly shaped loads.
Accurate Labeling
Proper labeling can minimize handling and improve efficiency since LTL freight passes through multiple terminals and is handled by various personnel before arriving at its destination. Accurate and visible labels reduce the risk of misrouting, delays, and lost shipments. You should also take extra precautions by marking items “Fragile," "Do Not Stack," or "This Side Up" to reduce the risk of damage.
Detailed Documentation
Thorough documentation is key to protecting your freight and business during LTL shipments. Every shipment should include a complete and accurate Bill of Lading (BOL), which acts as a legal contract between the shipper and the carrier. The BOL should list details such as the type of goods, dimensions, weight, packaging type, special handling instructions, and NMFC (National Motor Freight Classification) codes. Inaccurate or vague information can lead to misrouting, incorrect freight class charges, or mishandling.
In the event of freight damage or loss, detailed records make it easier to file claims and prove that your shipment was properly prepared and classified. Supplementing the BOL with photos of the packaged goods before pickup can serve as valuable evidence to support claims and avoid liability.
If your company is consistently dealing with damage during LTL shipments, it may be time to consider a custom packaging solution. Standard boxes, pallets, or crates aren’t always designed to handle the unique dimensions, weight distribution, or fragility of your specific products. While custom packaging may carry a higher upfront cost, it can lead to long-term savings by reducing product loss, customer dissatisfaction, returns, and claims processing. For companies shipping high-value or sensitive products, the added investment is often well worth it.
Custom packaging allows you to tailor the protection to your specifications and can include custom-fit foam inserts, honeycomb paperboard, custom-sized corrugated boxes, or specially engineered crates that prevent movement. For oddly shaped or fragile items, custom solutions minimize excess space and reduce movement within the packaging, both of which are major causes of in-transit damage.
Our team of packaging engineers helped County Materials, a leading manufacturer of concrete and landscape products, create a one-piece container to transport heavy materials that provided better protection during transit. The container also reduced manual labor and eliminated water damage. Learn more about the challenge, goals, solution, and results from our case study.
From proper packaging and pallet optimization to accurate labeling and load stability, every detail matters in protecting your shipments. If your company is facing recurring damage or delivery issues, our packaging experts are here to help. Contact us today to learn how custom solutions and smart shipping practices can transform your LTL experience.
