The Center for Packaging and Unit Load Design (CPULD) at Virginia Tech and the National Wooden Pallet & Container Association (NWPCA) recently hosted the highly successful "Advanced Pallet Design" short course. The 2.5-day program brought together nearly 20 participants from 15 companies, spanning multiple U.S. states and two international locations. This unique program showcased the growing demand for advanced knowledge in pallet design, optimization, and performance.

The course was led by Dr. Laszlo Horvath, Director of CPULD, alongside Dr. Brad Gething and Kristen DeLack, PE from NWPCA. Combining their expertise, the instructors delivered in-depth lectures, software training, and hands-on lab activities, offering attendees a well-rounded, practical learning experience.

A key highlight of the course was the focus on the Pallet Design System (PDS), NWPCA’s advanced-level software used for designing and analyzing wooden pallets. Participants received extensive training on the capabilities of PDS, learning to use its state-of-the-art modules to solve real-world design challenges, such as:

  • Determining the strength of corrugated boxes and plastic pails supported on wooden pallets.
  • Designing long pallets for flexible products like shingles using the innovative sheet-goods model in PDS.
  • Understanding how pallet stiffness directly affects packaging performance, particularly the strength of corrugated boxes and plastic pails.

By mastering these advanced tools, attendees were able to explore strategies to optimize pallet designs, reduce costs, and ensure supply chain performance.

In addition to classroom instruction and software training, participants had the unique opportunity to engage in hands-on activities at CPULD’s state-of-the-art labs. One of the most exciting activities involved breaking pallets using specialized testing equipment to analyze their performance under stress. This practical experience allowed attendees to see firsthand how pallet designs react to different loads and forces, reinforcing concepts learned in the classroom.

The combination of theory, software applications, and physical testing provided attendees with a comprehensive understanding of how pallet and packaging systems interact within the supply chain. Throughout the course, participants gained critical insights into a variety of advanced topics, including:

  • Fundamentals of unit load design and performance optimization.
  • Specifying industrial packaging materials and conducting supply chain audits to identify opportunities for improvement.
  • The role of load-bridging in reducing pallet costs by improving weight distribution across pallets.
  • Practical approaches to addressing real-world pallet and packaging challenges.

The leaders emphasized the importance of advanced training in pallet and unit load design, noting that tools like PDS, combined with physical testing, are revolutionizing the industry. The combination of software training and hands-on lab work ensured attendees left with practical, actionable knowledge they could implement immediately.

Participants developed a deeper understanding of advanced pallet design and an appreciation for how physical testing and software analysis can work together to optimize results. Many expressed enthusiasm for applying what they learned in their work and for attending future training opportunities.

The participation of industry professionals from diverse companies and countries also created valuable networking opportunities, fostering collaboration and idea-sharing among attendees. The success of this short course highlights CPULD and NWPCA’s ongoing commitment to education and innovation in the pallet and packaging industries.

For more information on upcoming short courses or to learn how advanced training can benefit your organization, visit CPULD’s website or contact the team directly: https://www.unitload.vt.edu/education/continuing-education.html