Load stability refers to how securely goods are stacked, wrapped, and secured on pallets for storage and transport. A stable load resists movement, shifting, or tipping during handling, shipping, or warehousing. In logistics, poor load stability leads to product damage, supply chain delays, increased costs, and even serious health and safety risks. Effective load stability improves supply chain resilience, protects brand reputation, reduces waste, and boosts operational efficiency. With growing focus on sustainability and customer satisfaction, businesses must ensure their pallets are not only secure but optimised for performance - balancing security, efficiency, and environmental responsibility.
Load stability
SAVE TIME,
MONEY &
INCREASE
EFFICIENCY.
At Castle, we offer a comprehensive range of load stability options, for a wide variety of uses. Our unparalleled expertise in the pallet wrap industry allows us to provide solutions tailored to meet the specific needs of our customers.


Alongside our state of the art testing centre, our team of highly trained load stability experts are some of the best in the business.



Ben Thompson
Load Stability Specialist

Alongside our state of the art testing centre, our team of highly trained load stability experts are some of the best in the business.

Ben Thompson
Load Stability Specialist

FOUR STEP PROCESS
Learn more about the industry leading process for taking our customers from nightmare inefficiencies, to fully optimised processes that transform their day to day operations.
01
02
03
04
01
Initial Meeting
One of our load stability specialists will have an initial meeting with you, either over the telephone or through an online meeting, to discuss briefly your current process for wrapping pallets. This will include details such as the maximum weight of pallet being shipped, number of pallets wrapped per day, the current film used, type of machinery on-site and to discuss any issues you might be experiencing when shipping your goods.

02
On Site Consultation
The next step is a site visit. We assess and test the current wrapping process, which will include the current pallet load stability figures, cost per pallet wrapped, consumption of plastic/CO2 per pallet wrapped and the performance of you machinery. We then test our Shield Films and compare the results. We use state of the art testing equipment, which will provide accurate data, showing the improvement in load stability that can be achieved. Our experts are able to make any necessary changes to existing equipment to get the best out of the film, or advise replacement/ alternative equipment if the findings show there can be a very quick return on investment.

03
Findings & Report
We will produce a very informative report, which we will go through with you, step by step. We will highlight the next step, which would usually be a film trial. We are so confident that our film will be a success, the trial pallet is offered on a sale or return basis! If you opt to invest in new machinery we will manage the set up process for you.

04
Ongoing Management
You will have a dedicated Load Stability Account Manager who will promptly process orders and give over the telephone advice if required. As part of our load stability package, one of our team will attend your site(s) and carry out regular testing, to ensure the wrap and machinery are performing as they should be. We will also keep you updated with new innovations that we bring to market, ensuring that you are always offered the best products available.

01
Initial Meeting
One of our load stability specialists will have an initial meeting with you, either over the telephone or through an online meeting, to discuss briefly your current process for wrapping pallets. This will include details such as the maximum weight of pallet being shipped, number of pallets wrapped per day, the current film used, type of machinery on-site and to discuss any issues you might be experiencing when shipping your goods.
02
On Site Consultation
The next step is a site visit. We assess and test the current wrapping process, which will include the current pallet load stability figures, cost per pallet wrapped, consumption of plastic/CO2 per pallet wrapped and the performance of you machinery. We then test our Shield Films and compare the results. We use state of the art testing equipment, which will provide accurate data, showing the improvement in load stability that can be achieved. Our experts are able to make any necessary changes to existing equipment to get the best out of the film, or advise replacement/ alternative equipment if the findings show there can be a very quick return on investment.
03
Findings & Report
We will produce a very informative report, which we will go through with you, step by step. We will highlight the next step, which would usually be a film trial. We are so confident that our film will be a success, the trial pallet is offered on a sale or return basis! If you opt to invest in new machinery we will manage the set up process for you.
04
Ongoing Management
You will have a dedicated Load Stability Account Manager who will promptly process orders and give over the telephone advice if required. As part of our load stability package, one of our team will attend your site(s) and carry out regular testing, to ensure the wrap and machinery are performing as they should be. We will also keep you updated with new innovations that we bring to market, ensuring that you are always offered the best products available.


PRODUCTS
Case Studies
“WE’VE SEEN A REDUCTION OF 73% IN PLASTIC & CO2”
CARPETRIGHT, PURFLEET, UK
We helped this household name brand to transform their packaging operations, making significant savings that helped them in both cost and ecological efforts to improve the company…
CASE STUDIES
L'OREAL
When L’Oréal’s Trafford Park distribution center faced a challenge to reduce plastic waste in 2020, Dave Potts, Order Prep Manager, turned to Castle Industrial Supplies for a solution. By leveraging Castle’s expertise in load stability and packaging analysis, L’Oréal achieved remarkable results: a 50% reduction in shrinkwrap usage, equating to 13 tons of plastic saved annually, and a nearly 50% reduction in costs.
Discover how Castle’s tailored approach not only met L’Oréal’s sustainability goals but also enhanced operational efficiency and quality, setting a benchmark for distribution centers worldwide.


CARPETRIGHT
We worked very closley with the CarpetRight warehouse team to provide comprehensive load stability testing and expert analysis. Through our process, we identified opportunities to improve their pallet-wrapping efficiency and optimise their materials. By optimising our tailored solutions, the client achieved significant improvements in load stability, cost efficiency and and sustainability. Our approach combines advanced testing, industry-leading products, and dedicated support, ensuring measurable benefits for every customer we worked with.
This case demonstrates our ability to deliver customised, impactful results that align with our clients’ goals.

Load
Stability
Testing
Centre
Committed to providing our customers a best in class service, when it comes to load stability, our world class facilities provide the full range of tests and data you need to optimise your operations to the max.
Easily accessible, just off junction 35 of the M6, our Oakwood site is perfect for companies looking to review their practices and products. In fact, we’re the only packaging specialists in the UK to feature the scale of machinery and expertise so making a visit is essential if you’re considering your pallet load stability.






FREQUENTLY ASKED QUESTIONS
What is load stability and why is it important in logistics?
How can load stability testing reduce supply chain damage?
Load stability testing identifies weaknesses in how goods are secured to pallets. Using controlled simulations like tilt, vibration, and acceleration tests, we replicate real-world conditions such as braking, cornering, and rough handling. This highlights points where loads might shift, collapse, or fail. By testing and optimizing materials, wrapping techniques, and stacking patterns, businesses can dramatically reduce transport damage, minimise returns, and enhance product protection. Fewer damaged goods mean lower costs, stronger customer relationships, and less environmental waste - directly strengthening your entire supply chain performance.
How can improving load stability lower my shipping costs?
Better load stability often means fewer damaged goods, fewer rejected deliveries, and fewer costly replacements. It can also allow for safer and more efficient stacking, enabling you to maximise trailer or container space. Optimised wrapping techniques can reduce the amount of pallet wrap used per load, saving on material costs. By preventing overuse of protective materials and minimising transport damage, businesses create a leaner, more cost-effective shipping process. In addition, a stable load can reduce insurance claims and the need for extensive secondary packaging, further lowering operational expenses.
How does load stability affect brand reputation?
Unstable loads can cause product breakages, leaks, and contamination during transit, putting customers at risk and increasing the chance of costly recalls. Damaged goods harm your brand’s image, especially if they reach consumers or key retail partners in poor condition. Repeated product failures due to load instability erode trust and can permanently impact relationships with customers and distributors. By investing in professional load stability testing, businesses can protect not just their products, but their reputation for quality, reliability, and operational excellence.
How do I know if my pallet loads are stable enough for transport?
The best way to be certain is through professional load stability testing. Visual inspection alone can miss underlying weaknesses. Warning signs that your loads may not be stable enough include visible leaning, loose wrap, shifting during handling, or consistent damage claims during transport. Our testing services simulate real-world transport forces to accurately measure containment force, deformation, and tipping risks, giving you clear, actionable feedback on whether your loads meet industry standards and best practices.
Can you help us achieve compliance with load stability regulations?
Yes. We understand the growing pressure around transport safety regulations and retailer requirements. Our testing and reporting services can help you meet industry standards (such as EUMOS 40509) and provide documented evidence of due diligence, improving compliance, customer confidence, and supply chain resilience.