UNIT LOAD

CONCEPT
UNIT LOAD

Unit Load is the amount of material that can be moved as a

single mass between two locations.

Unitization of load is an important concept in Materials

Handling. The basic concept is to move maximum load at a
time so that the number of moves for a definite quantity of load
to be moved is minimum and so is the cost of handling.
UNIT LOAD

There are many materials which by virtue of their size and

weight need to be moved individually and are called Unit Loads.

However, there are many materials whose individual size and

weight is small, but are required to be moved in large quantities.
Such materials, and also bulk materials which are needed in
specific quantities, are generally gathered together to form a
load of a definite weight, and then moved as an unit load. This
is called Unitization of Load.
UNITIZED LOAD

Unitized load may be defined as: ‘‘A number of items, or bulk

material, so arranged or restrained that the mass can be picked
up and moved as a single object, too large for manual handling,
and which upon being released will retain its initial arrangement
for subsequent movement. It is implied that single objects too
large for manual handling are also regarded as unit loads.’’
UNIT & UNITIZED LOAD

Often the two terms ‘‘unit-load’’ and ‘‘unitized load’’ are used
interchangeably. However, in this discussion, unit load will
mean a single object where unitized load will mean collection of
objects which are being treated as an unit load for handling it.

A few examples of unitized load are:

(i) Bundle of sticks tied together.
(ii) Small castings put inside a container.
(iii) A stack of bricks on a pallet.
(iv) A trailer full of sand etc.
ADVANTAGES

The major advantages of unitization and handling of unit loads are:

a. It permits handling of larger loads at a time and thereby reduces

handling and transportation costs.
b. Loading and unloading time of unit load is substantially less
than when handled as loose/ individual material.
c. Unitized loads are less susceptible to damage and loss during
movement from one place to another.
d. It offers safer handling and transportation compared to those of
loose materials.
ADVANTAGES

e. Unitized load, even made of irregular shaped items, generally

become stable and well shaped.
f. For unitized load, individual item labeling may be avoided.
g. The process of unitization often protects loads from foreign
elements.
h. Unitization generally provides a basis for standardization of
handling system and equipment within the plant as well as at
the receiving and shipping points for transportation.
DISADVANTAGES

There are also disadvantages associated with unitization of

loads. These are:

a. There is a cost of unitization and de-unitization.

b. Unitization generally involves additional support and
material for restraining the loose articles. These unitization
medium increase the weight of the final load to be handled
c. Unitization essentially means deployment of equipment,
which necessitates capital investment.
DISADVANTAGES

d. Containers are often used for unitization. Movement of the

empty containers results in additional handling cost and
problem.
e. There is possibility of damage due to mishandling of large
amount of load.
f. Movement of unitized materials may get hampered due to
absence of transfer equipment.
LOAD UNITIZATION PROCESSES & HANDLING METHODS

Based on the process of unitizing and methods employed for

handling, unitized loads are generally grouped into following
five basic types:

1. Unit load on a platform

2. Unit load in a container
3. Unit load on a rack
4. Unit load on a sheet
5. Self contained unit load
LOAD UNITIZATION PROCESSES & HANDLING METHODS

1. UNIT LOAD ON A PLATFORM

When the load is arranged on a platform which can be lifted

and carried as unit load. Generally two types of platform are
used in industry - pallet and skid.
LOAD UNITIZATION PROCESSES & HANDLING METHODS

2. UNIT LOAD IN A CONTAINER

When small sized articles are put inside a box like

container, which can be carried easily by trucks, cranes etc.
This is a type of unitized load which is very popularly
practiced in manufacturing industries. Different sizes and
designs of containers are used like box, bin, crate, carton,
sack / balloon etc.
LOAD UNITIZATION PROCESSES & HANDLING METHODS

3. UNIT LOAD ON A RACK

Specially designed racks are used to hold different types of

parts in desired orientation or relationship to each other. The
racks may be provided with inserts, pegs, or holes to orient
parts or to form dividers between layers for easy handling,
counting, inspection etc. Long products like pipes, bars etc.
are essentially stored in racks.
LOAD UNITIZATION PROCESSES & HANDLING METHODS
LOAD UNITIZATION PROCESSES & HANDLING METHODS

4. UNIT LOAD ON A SHEET

Unitization is possible on a sheet material and the shape of

the load depends on the character and way the sheet
material is used. Flat sheets like cardboard, chipboard or
plywood may be used for unitization of load on it. Specially
formed molded sheets are used for unitization of bulk
materials. In these formed sheets, provisions are kept for fork
entry of lift trucks.
LOAD UNITIZATION PROCESSES & HANDLING METHODS

5. SELF CONTAINED UNIT LOAD

Self contained unit load (not requiring major auxiliary aids):

Different kinds of self contained unitized loads are practiced
in industry and in everyday use. There are:
a) Bundle
b) Bale
c) Fastened Unit Load
d) Interlocked Unit Load
e) Unrestrained Unit Load
LOAD UNITIZATION PROCESSES & HANDLING METHODS

5. SELF CONTAINED UNIT LOAD

a) BUNDLE: Long pieces of unequal shapes tied together by a rope,

wire, elastic band etc. for ease of handling.

b) BALE: Materials like scrap paper, sheet metal trimmings etc. are
compressed in a bailing press to make the loose materials into a
single compact load of reduced size.

c) FASTENED UNIT LOAD: Loose items fixed in position by

materials like wrapper, tape, glue etc.
LOAD UNITIZATION PROCESSES & HANDLING METHODS

5. SELF CONTAINED UNIT LOAD

a) INTERLOCKED UNIT LOAD: Load which consists of individual

pieces so shaped by design that they can be arranged in a
fashion to make the assembly interlocked and self restrained. For
example cast aluminum pigs interlocked to build a stack.

b) UNRESTRAINED LOAD: Items stacked on a lifting device without

any restraining member, such that it can be stored as an unit, but
requires extra care for lifting or moving. Stack of bricks or cartons
on a pallet are examples of unrestrained load.
PALLETS, SKIDS & CONTAINERS

Pallets, skids, and containers are the most commonly used

unitization devices, referred in the previous section. Both pallets and
skids are platform type devices used for forming ‘‘Unit load on
platform’’

 PALLET: It is essentially a platform used for assembling, storing

and handling of materials as a unit load. Essential feature of a
pallet is that the forks of a lift truck can be inserted at the bottom
side of the platform, while the pallet is resting on floor and thus
can raise the pallet with load and move it to desired place.
PALLETS, SKIDS & CONTAINERS

 SKID: It is essentially a platform provided with legs so that a

platform truck may get inside it and raise it from ground. Skids are
thus single-faced and non-stackable.

 CONTAINER: Different types of containers of various sizes from

small to large made out of diverse materials like sheet metal, wire
net, wood, plastics, rubber, paper etc. are used for unitization of
loads in industry. The term container includes parts bin, tote pan,
tote box, pallet box, bulk container, cargo container, van/shipping
container etc. Containers are of different designs.
PALLETS, SKIDS & CONTAINERS
PALLETS, SKIDS & CONTAINERS
PALLETS, SKIDS & CONTAINERS
PALLETS, SKIDS & CONTAINERS
ALTERNATIVE METHODS OF HANDLING

There are alternative methods of handling unitized loads

without using unitizing devices like pallet, skids, containers
and racks. These alternative methods make use of different
attachments used in conjunction with materials handling
equipment like forklift truck, crane etc. The unit load which
are handled by these methods are generally single items or
unitized loads of regular size and shape like rolls, bales,
cartons, bags etc.
ALTERNATIVE METHODS OF HANDLING

Advantages of using these alternative methods are:

i. No need of moving weighty and bulky devices like
pallets, containers etc.
ii. Lower operating cost.
iii. Flexibility in storage as warehouses are not limited to
a few size of palletized / containerized loads.

There are also some disadvantages of these methods:

i. These are not suitable for less than unit loads.
ii. Mixed size loads cannot be stacked effectively.
PACKAGING FOR MATERIALS HANDLING

Packaging of materials has two major aspects. The one is to

package individual product/item to promote sale of soft goods.
The other is to protect the materials, individual or bulk, during
storage and transportation of these packaged materials.

Packing is to provide protection for an article or group of

articles against physical damage during
shipment/transportation.
PACKAGING FOR MATERIALS HANDLING

Different types of industrial packaging are practiced in industries,

depending on the items/goods to be packed. Some of these are:

1) WOODEN BOXES
2) WOODEN CRATES
3) CORRUGATED PAPER CARTONS
4) SHRINK-WRAPPING OR STRETCH-WRAPPING
PACKAGING FOR MATERIALS HANDLING

WOODEN BOXES/CRATES

By definition Wooden case or box is a framework whose base

is based on a sill or skid, and all the other five sides are
covered by sheathing made of wooden planks or plywood,
used as a container to transport articles providing complete
protection to the articles. Wooden crate is a framework used as
a container in the transportation of articles which do not require
complete protection afforded by a wooden case or box.
PACKAGING FOR MATERIALS HANDLING

WOODEN BOXES/CRATES
PACKAGING FOR MATERIALS HANDLING

CARTONS

Cartons, made of corrugated paper or plastic materials or solid

fiberboard are used for packing a number of smaller goods with
or without soft sales packaging.
PACKAGING FOR MATERIALS HANDLING

SHRINK WRAPPING

In shrink-wrapping, polyvinyl chloride (PVC) or polyethylene

(PE) film of 50-350 micron thickness, is used to wrap the load
arranged over a pallet and then heated by a portable hot air
gun or some heat source at a temperature range of 350°C from
a distance of about 300mm. With the application of heat the
film shrinks and wraps the loads together to form a stable unit
load.
PACKAGING FOR MATERIALS HANDLING

SHRINK WRAPPING

Major advantages of shrink-wrapping are:

 Can be used for articles almost of all shapes

 Stable pallet loads are formed
 Protects unitized load from dust, dirt and even moisture
 Protects articles from damage and loss
 Relatively low cost method of unitization and packaging
 Transparent film allows the wrapped articles visible
PACKAGING FOR MATERIALS HANDLING

SHRINK WRAPPING
PACKAGING FOR MATERIALS HANDLING

STRETCH WRAPPING

Stretch wrapping is the latest and most cost-effective method of

unitizing pallet loads. Here high stretchable polyethylene film is
wrapped under tension round the loads. Multiple wraps are
generally employed, when the film gets attached to the load
surfaces and make it an unitized load.
PACKAGING FOR MATERIALS HANDLING

STRETCH WRAPPING

However, additional advantages over those of shrink wrapping

are:

 Costs less
 Requires less energy
 Holds piece loads together
 Can be used for heat sensitive products.
PACKAGING FOR MATERIALS HANDLING

STRETCH WRAPPING
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