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Lecture 9-
Unitisation
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Section 1 Unitisation
Section 2 Pallets
Section 3 Roll Cages
Section 4 Tote Bins
Section 5 Containers
Section 6 Unit Load Devices (ULD)
Section 7 Other Unit Loads
UNITISATIONLECTURE STRUCTURE
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UNITISATIONHISTORIC GENERAL CARGO OPERATIONS
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Small quantities of non-standard cargoBoxesCratesDrumsBags
Fragmented distributionLarge numbers of shippers Cargo loaded at local ports Multi-port itineraries
Constraint on trade
UNITISATIONCHARACTERISTICS OF GENERAL CARGO
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Difficult stowage requirements High cost operations Labour
Very labour intensive Low handling rates
VesselVery low vessel productivity Long delivery times High freight rates
Poor cargo quality control
UNITISATIONGENERAL CARGO - HANDLING ISSUES
Productivity of conventional cargo handling (Tonnes per portworker per year)
1980s 1990s % Improvement
3,137 Tonnes
4,029Tonnes 28%
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UnitisationThe assembly of separate cargo packages into a single load which has standard dimensions to allow for mechanical handling and ease of stowage for transport
StowageThe act of placing cargo in an aircraft or ship in a manner that provides for the safety of the vessel and the cargo, optimises available space and allows easy access to the cargo at the place of dischargeMay be used for any form of cargo – bulk, container, breakbulk etc.
UNITISATIONDEFINITIONS
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Uniformity of shape Standard size (dimensions)Standard weights (to maximum)Gives strength to prevent crushingCapable of being stackedSuited to mechanical handling
UNITISATIONCHARACTERISTICS OF UNIT LOADS
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UNITISATIONUNIT LOAD TYPES
ISO container Unit load device
Pallet
Non-ISO container Other
Tote binsRoll cages
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Labour productivity and safety increasedManpower requirements reduced
UNITISATIONLABOUR PRODUCTIVITY
Productivity of conventional cargo handling (Tonnes p/per annum)
Conventional Cargo Containerised Cargo Difference
1980s 3,137 24,948 795%1990s 4,029 46,662 1,158%
% Improvement 28% 87%
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Speed of handling increasesHandling process simplified
Specialized handling equipmentStandard (repetitive) handling
Reduces need for tallying individual items (counting)Handling costs reduced
Payload per move increasedVehicle / ship turnaround time decreasedHigher utilisation of warehouse & transport space
UNITISATIONHANDLING BENEFITS
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Unit loads are more stableSecured to a palletStored in a container
Likelihood of damage is reducedCrushingHandlingDeliberate damageTransport movement
Reduced insurance costsImproved quality of service
UNITISATIONDAMAGE PROTECTION
385
Containerised cargoConventional cargo
Palletised cargo
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Portworkers do not directly handle cargoReduces
Opportunity for pilferageVisibility of cargo
Security systems (seals)
UNITISATIONSECURITY
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Improved stowageReduced damageHigher handling efficiency & labour productivityIncreased securityEasier planningSimplified tracking
UNITISATIONADVANTAGES
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Section 1 Unitisation
Section 2 Pallets
Section 3 Roll Cages
Section 4 Tote Bins
Section 5 Containers
Section 6 Unit Load Devices (ULD)
Section 7 Other Unit Loads
UNITISATIONLECTURE STRUCTURE
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Basic unit load technologyConstruction
WoodSteelPlastic
Wide range of sizes and designs
PALLETSCHARACTERISTICS
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Book - each 210×118mm, weighing 0.0375kg
Shrink wrapped into bundles of 100
Packed into boxes - four bundles shrink wrapped together (weight 15kg)
Palletised – 32 boxes per pallet
PALLETSCREATING A LOAD
32 boxes (12,800 booklets)
1 Move!
1 booklet1 bundle
(100 booklets)1 box
(4 bundles / 400 booklets)
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Cargo will only be protect if pallet is loaded correctly
PALLETSSECURING CARGO
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Load should be secured within the base area of the palletShrink wrap used to secure cargoMay be applied manually or by automated machines
PALLETSSECURING CARGO
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Primary cause of product damageReduces strength of goods stacked on pallet
Creates problems for Handling equipmentStorage in warehouse racking
PALLETSPALLET OVERHANG
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Pallet truckWarehouse based equipmentPedestrian controlled and manually operated
Fork lift truckWarehouse transfersTo / from vehicles
Automated warehousing systemsWithin storage facility
PALLETSHANDLING
Pallet truck
Fork lift truck
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Suitable for a wide variety of goodsStorage & handling
Greater product packing densityStored items can be delivered without repackingFast access to stored goodsCan be lifted with a simple fork lift truck
TransportingSuited to most commercial vehicles
ReusableCost effective
PALLETSADVANTAGES
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Different size standardsCapacity restricted to 1.5 tonnesOnly offers limited protectionRange of qualityWooden pallets have a limited life ~ 4 tripsNon-wooden pallets more expensiveDamaged pallets may damage cargoReturn and maintenance of pallets
PALLETSDISADVANTAGES
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Asia 1100 x 1100 mmEurope 800 x 1200 / 1000 x 1200 mm dominate
> 280 million pallets in use> 30 different sizes and types
North America 48 x 40 inches
PALLETSSIZES AND STANDARDS
Euro-pallet Industrial pallet Asia pallet
Four-way-entry-pallet Four-way-entry-pallet Four-way-entry-palletD i m e n s i o n
800 x 1200 mm 1000 x 1200 mm 1100 x 1100 mm
L o a d - b e a r i n g c a p a c i t y1500 kg 1500 kg 1300 kg
E x t r a l o a d6000 kg 6000 kg 5200 kg
D e a d l o a d25 kg 30 kg 30 kg
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Pallet size impacts loading profile in road trailers / containersImpacts loading efficiency
PALLETSLOADING PROFILES
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PALLETSCONTAINER LOADING PROFILES
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PALLETSPALLET SHIPS
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Section 1 Unitisation
Section 2 Pallets
Section 3 Roll Cages
Section 4 Tote Bins
Section 5 Containers
Section 6 Unit Load Devices (ULD)
Section 7 Other Unit Loads
Section 8 Terminology & Concepts
UNITISATIONLECTURE STRUCTURE
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Usually steel with mesh bottoms, sides and shelvesFitted with wheels
Manually pushedCollapsible
For efficient storage when empty (nested)
ROLL CAGESDESCRIPTION
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Common in the retail sector for delivery to shopsCarry wide range of items
ClothingGrocery items
Typically owned by users
ROLL CAGESUSES
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ManualIndividual pushes / pulls cage
Electric Tug (Mover)Prevents tipping on uneven surfacesMultiple cages can be moved at one time
Towing linksReduces potential of injuries or operator fatigueCompact and easy to store
ROLL CAGESHANDLING
Roll cage tug
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Sides of roll cage contain loadShrink wrap not requiredStacking less important
Wheeled Permits faster loading and unloading of vehiclesForklift truck not required
May be designed to provide product security (lockable doors)More efficient in restocking retail shelves
ROLL CAGESADVANTAGES OVER PALLETS
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Expensive – 10 times cost of palletTime required to manage use
Repairs can be costlyDifficult to cleanRequire considerable space when not in use
Noisy when movedMay not be used in warehouse racking systems
ROLL CAGESDISADVANTAGES OVER PALLETS
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Section 1 Unitisation
Section 2 Pallets
Section 3 Roll Cages
Section 4 Tote Bins
Section 5 Containers
Section 6 Unit Load Devices (ULD)
Section 7 Other Unit Loads
UNITISATIONLECTURE STRUCTURE
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Vary in sizeEg. x 400mm x 300mm high
May be open top or with lidStackableWhen empty may be
Stored in side each other orCollapsed
Suited to automation
TOTE BINSDESCRIPTION
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May be usedWithin a single siteWithin a supply chain
Storage and handling of small itemsDistribution of fragile / perishable items
Bread & cakesVegetables
TOTE BINSUSES
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Bases fitted with wheelsDesigned for loading (stacking) tote bins and plastic traysOften used in warehouses and retail distribution
TOTE BINSDOLLIES
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AdvantagesLess expensiveLess likely to be damagedNo need for assembly or disassemblyFlexible loading height – no fixed sidesSave 80% space required for roll cagesFewer accidentsEasier to clean
DisadvantageMay only be used with modular loads (eg tote bins)
TOTE BINSDOLLIES OVER ROLL CAGES
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TOTE BINSCOMBINING UNIT LOADS
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Section 1 Unitisation
Section 2 Pallets
Section 3 Roll Cages
Section 4 Tote Bins
Section 5 Containers
Section 6 Unit Load Devices (ULD)
Section 7 Other Unit Loads
UNITISATIONLECTURE STRUCTURE
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CONTAINERSDESIGNS
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CONTAINERSFLEET
Source: Containerisation International, Market Analysis – World Container Census 2010
Global container fleet (2009) TEU Units
General container 23,523, 131 15,468,372
Special containers 948,691 661,936
Reefer containers 1,689,184 918,336
Tank containers 204,483 201,080
Total 26,365,489 17,249,724
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Capital intensiveTerminal infrastructureTransport infrastructureContainer ownership costs
Complex managementTerminal storageContainer flowsEmpty container storage & flows
Specialized cargo requirementsTemperature sensitiveMoisture content….
Allow consolidation of small shipment loads
CONTAINERSCHARACTERISTICS
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Non-governmental organisation (NGO) based in SwitzerlandProduces voluntary industry standards (not just transport)Widely used in logistics and transport
Standardisation of pallet dimensions, maritime containers
CONTAINERSSTANDARDS
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CONTAINERSPAYLOAD
Payload = Max Gross Weight – Tare Weight
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Used globallyStandard strength and dimensions
Strong, stackableMany years life expectancyStandard mechanical handling methodsSuited to ship, rail, road & inland waterway
Allows consolidation of loads1 container = up to 28 tonnes cargo
Mature technologyRange of designs with units for specific cargo typesWhile still conforming to the standards
Cargo protectionImproved securityReduced packagingReduced damageEasy to identify tampered containers
CONTAINERSADVANTAGES
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AdvantagesGood for mixed cargos in single containerEasier handling of cargo packaged with different shapesReduced cargo damage from handlingStacking inside containerImproved handing speedReady for warehouse handling and storageFor LCL it retains integrity of individual shippers cargo
Less than container loadDisadvantages
Reduced cargo weight per containerReduced cargo space per container
CONTAINERSUNIT LOADING IN CONTAINERS
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Non-palletisedBooklets - each 210×118mm, weighing 0.0375kg
Shrink wrapped in to bundles of 100Packed into boxes - four bundles shrink wrapped together (weight 16kg)
850 cartons can be loaded into 20ft containerPalletised
32 boxes per pallet640 cartons loaded into 20ft container
25% reduction in the number of booklets loaded
CONTAINERSPALLETISED VS NON-PALLETISED
850 loose cartons (340,000 booklets)
32 cartons (12,800 booklets)
640 cartons (256,000 booklets)
VS
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Standard handling technologyImproved handling productivityEasily transferred between transport modesEconomies of scale for equipment manufacturers Encourages R&D in equipment design
Design facilitates dense storage (height & block)Stacking height influenced by
Container weight (empty / full)Type of container (reefer, rack etc)Availability and type of handling equipmentAccessibilityLikely dwell time
CONTAINERSHANDLING
ISO container
Stacking limits
9 high - 20’7 high - 40’ / 45’
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Designed for specific cargo / shipper / tradeDo not conform to ISO standards
Strength, dimensions, payloadMay or may not be suited to twist lock handling
Non standardStackingHandlingLoadingTransportation
Closed system Often owned by individual shipperEmpty containers returned to shipper for reuse
CONTAINERSNON-ISO CONTAINERS
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US 53ft containerGreater volume - limited to US market (inc Hawaii)
European 2.5m & 2.55m wide trailerDesigned specifically for use with the Euro Pallet
CONTAINERSNON-ISO EXAMPLES
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Originated from AmericansUsed in Japan, China & Korea
Carry merchandiseJeju tangerines
AdvantagesSuited to small volumesCan be transported by air
CONTAINERSNON-ISO EXAMPLES – 12FT CONTAINERS
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CONTAINERSSHIPMENT OF WIND TURBINES
Source: www.matts-place.com/intermodal
Wind turbine blade shipment
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Section 1 Unitisation
Section 2 Pallets
Section 3 Roll Cages
Section 4 Tote Bins
Section 5 Containers
Section 6 Unit Load Devices (ULD)
Section 7 Other Unit Loads
UNITISATIONLECTURE STRUCTURE
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UNIT LOAD DEVICES (ULD)CONVENTIONAL VS UNITISED AIR CARGO
Conventional air cargo
Unitised air cargo
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Unit loads specifically designed for air transportLightweight - aluminiumProfile shape of aircraft hold
Reduces the number of items to be loadedSpeeds up turnaround of aircraft
Based on international standardsDeveloped by IATA (International Air Transport Association)
UNIT LOAD DEVICES (ULD)DESCRIPTION
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Characterised by TypeBase dimensionsPhysical details
ShapeLoad restraintHandling requirements
Two formsPallets
Sheets of aluminiumInclude rims designed to lock onto cargo net
ContainersAlso known as cans and podsUsually made of aluminiumMay have built-in refrigeration units
UNIT LOAD DEVICES (ULD)FORMS
ULD Pallet
ULD Container
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UNIT LOAD DEVICES (ULD)ULD PALLETS
Source: www.startupboeing.com
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UNIT LOAD DEVICES (ULD)ULD CONTAINERS
Source: www.startupboeing.com
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UNIT LOAD DEVICES (ULD)ULD CONTAINERS
Source: www.startupboeing.com
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UNIT LOAD DEVICES (ULD)MAIN DECK & BELLY MD-11
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Specialist handling systemsPowered fixed conveying systems of tracks fitted with rollers transport the ULD onto the aircraft and within itCapable of rotating a ULD through 90o to position correctly within the plane
Hi-loadersLift and position ULD / cargo at hold door
Larger heavy-lift aircraft may be accessed by front or rear doors that lower to ground level allowing certain cargo to be loaded by fork lift truck
UNIT LOAD DEVICES (ULD)HANDLING
Hi-loader
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UNIT LOAD DEVICES (ULD)HANDLING
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UNIT LOAD DEVICES (ULD)AIRPORT STORAGE
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Limited transferability between transport modesLimited ability to stack when on the groundSpecific to aircraft typeEasily damaged with improper handling
UNIT LOAD DEVICES (ULD)CHALLENGES
Airline direct spend on ULD repair is estimated at US$ 150-200 million a year
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Section 1 Unitisation
Section 2 Pallets
Section 3 Roll Cages
Section 4 Tote Bins
Section 5 Containers
Section 6 Unit Load Devices (ULD)
Section 7 Other Unit Loads
UNITISATIONLECTURE STRUCTURE
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Commodity specificWide range depending on commodity and tradeAssociated with minor dry bulk trades
AdvantagesMaximizes payload for cargo typeIncreased handling productivityReduction in manual handlingReduction in damage
ChallengesSpecialist handling equipmentProtection level variesRequires volume shipments / trade flowWho invests in equipment?
OTHER UNIT LOADSOVERVIEW
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OTHER UNIT LOADSINTERMEDIATE BULK CONTAINERS
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Unitised transport of bulk cargosWineChemicalsPowders
Incorporated pallet base to aid mechanical handlingMay be stacked
OTHER UNIT LOADSINTERMEDIATE BULK CONTAINERS
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Also calledFlexible Intermediate Bulk Container Jumbo BagTote bag
Made from plastic / fabricLow-cost and efficient transportation
Bulky goods – sand, gravelLight weightStrong
Suited to mechanical handling
OTHER UNIT LOADSTONNE BAGS