The stability of palletized corrugated board packaging is crucial for safe transportation and storage. Offset stacking, where packages are slightly shifted relative to those in lower rows, is a common technique to enhance pallet stability. However, this method can compromise the load-bearing capacity of the packaging. This study investigates the impact of offset stacking on the load-bearing capacity of cardboard packaging during palletization. While offsetting packages on a pallet can enhance stability, it adversely affects the load-bearing capacity of the packages. This is particularly critical as the load from upper packages is primarily transferred through the walls, and their misalignment can significantly reduce their structural integrity. Our research indicates that such reductions in load-bearing capacity can reach up to several percent.

Advanced numerical modeling using the Finite Element Method (FEM) was employed to estimate the decrease in load-bearing capacity due to offset stacking. This method allows for a detailed analysis of how misaligned walls affect structural performance under a load. The FEM analysis revealed that offset stacking leads to a notable reduction in the load-bearing capacity of the packaging. The structural integrity of the corrugated board is compromised, with load-bearing capacity reductions reaching up to 25% in some configurations.

This study highlights the trade-off between stability and load-bearing capacity in offset stacked cardboard packaging. The findings underscore the need for careful consideration in packaging design and palletization strategies to balance these competing factors. Future work will focus on optimizing stacking patterns and developing guidelines to mitigate the adverse effects on load-bearing capacity. This research provides valuable insights for the packaging industry, promoting safer and more efficient palletization practices while maintaining structural integrity.