Efficient Unit Loads affect the entire processes chain. Shipping units start their life at the plant of the manufacturer, are fed through the production facilities and goods distribution systems of the consumer goods business. Their journey continues through the hands of several distributors to the central warehouses of retailers until they finally reach the store. One main condition for smooth operations in this process chain is the so-called modularity of shipping and warehouse units. Modularity means that the dimensions of secondary packaging – such as boxes – fit perfectly to the dimensions of tertiary packaging – such as pallets. Standardizing dimensions avoids that a pallet doesn’t fit into the storage cell, shipments are thrown off balance or goods have to be arduously restacked manually.

The ISO master module has the basic dimensions of 600 x 400 mm. Only if pallets, containers, shipping units, the loading space of shipping vehicles are modular in the sense of these basic dimensions – i.e. can be divided by or multiplied with a whole number – only then can loading or storage space be used efficiently and costs reduced. The most popular ISO module types are as follows:

By coordinating the modules of the different components in the logistics system, packaging and shipping carriers can be returned easily at various interfaces in the supply chain (production, shipping, distribution, warehousing and return). GS1 Germany’s Efficient Unit Loads recommendation only allows very limited scope for deviation. Stacked pallets leaving the manufacturer’s facility may not run-over the pallet at all, as the pallet is automatically pulled out at a check-point otherwise. In this case the pallet has to be stacked again manually. When pallets arrive in central warehouses or stores goods are only allowed to run-over the pallet by some millimeters.