Cutting-Edge Load Stability Techniques That Will Lower Your Packaging Expenses

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Our state of the art testing centre, based at our Oakwood offices, provides customers with real time, data driven analysis of their pallets. Helping them to optimise for more efficient packaging operations.
Click each stage of analysis to learn more.
Material Analysis
To provide customers with the complete advice we have become renowned for, we start our analysis by looking at the products currently used, and their materials makeup. This allows us to identify any correlations with consistent issues or problems the customer has experienced and offer an opinion on its stability potential.
Process Analysis
Once we have discussed the strengths and weaknesses of a customer's products, we lead the conversations toward the packing process. During which, we identify the reasons, as well as the pros and cons, for existing methods. Whether it's machinery or hand dispensers, we put it to the test and showcase a mix of alternatives.
Performance Analysis
Finally, we get the cargo prepped for testing by leading them into our tilt vibration bench and acceleration bench respectively. These allow us to simulate the rigours of transport to important standards, including eumos 40509. Then, we redress goods using our suggestions before comparing performance.
01
Material Analysis
To provide customers with the complete advice we have become renowned for, we start our analysis by looking at the products currently used, and their materials makeup. This allows us to identify any correlations with consistent issues or problems the customer has experienced and offer an opinion on its stability potential.
02
Process Analysis
Once we have discussed the strengths and weaknesses of a customer's products, we lead the conversations toward the packing process. During which, we identify the reasons, as well as the pros and cons, for existing methods. Whether it's machinery or hand dispensers, we put it to the test and showcase a mix of alternatives.
03
Performance Analysis
Finally, we get the cargo prepped for testing by leading them into our tilt vibration bench and acceleration bench respectively. These allow us to simulate the rigours of transport to important standards, including eumos 40509. Then, we redress goods using our suggestions before comparing performance.
Castle Industrial’s newly built testing centre provides a state of the art opportunity for businesses to back their processes with underlying data.
Angel Hernandez
President of EUMOS
Castle Industrial’s newly built testing centre provides a state of the art opportunity for businesses to back their processes with underlying data.
President of EUMOS
What is load stability testing, and why is it important
Load stability testing evaluates how securely and safely goods are stacked and wrapped on pallets during transport. Using advanced technology such as acceleration benches, tilt vibration benches, and precision wrapping machines, we simulate real-world handling and transport conditions. This testing identifies weaknesses in packaging methods, helping businesses prevent product damage, reduce operational costs, and enhance supply chain security. In today's environment, achieving the right balance between safety, efficiency, and sustainability is critical – and load stability testing ensures your packaging setup performs where it matters most.
Can you test different types of pallets and packaging materials?
Yes, absolutely. Our Load Stability Testing Centre is equipped to work with a wide range of pallet types, load configurations, and packaging materials. Whether you're using standard wooden pallets, plastic pallets, bespoke solutions, or various types of stretch film, corner boards, and secondary packaging, we can accurately test and optimize your specific setup. Our goal is to tailor solutions that work for your actual operations, not just theoretical scenarios.
How long does the testing process typically take?
The full testing process generally takes between one and three days, depending on the complexity of the loads and the range of variables being assessed. Material Analysis, Process Analysis, and Performance Analysis are all included – from studying your current materials and wrap properties to testing load resilience on vibration and acceleration benches. If required, we can also complete rapid assessments or longer in-depth projects, depending on your operational needs and timescales.
What data and reports will I receive after testing is complete?
You’ll receive a comprehensive, detailed report that includes:
Quantitative test results (tilt angles, acceleration thresholds, deformation levels)
Photographic and video evidence of testing
Analysis of current material and process performance
Recommendations for optimization, including technical settings, material changes, and wrapping techniques
Clear benchmarking against industry standards where relevant
Our reports are designed to be both technically robust and commercially actionable, providing your team with clear next steps to reduce damage, improve efficiency, and enhance supply chain security.
Do you offer on-site visits to evaluate our current load stability setup?
Yes. Before or alongside testing at our centre, our Load Stability Specialists can visit your site to carry out a full evaluation of your current palletizing and load securing methods. This allows us to see your challenges firsthand, capture operational data, and ensure that the recommendations we make are fully aligned with your specific environment and logistics flow.
Do you provide training for our staff on improving load stability?
Yes, we do. We believe that the best results come when people, processes, and materials all work together. Our training sessions can be tailored to your team, covering best practices for pallet wrapping, load building, machinery use, and handling techniques. We also offer guidance on real-time process checks and improvements, helping your warehouse or logistics staff embed stability-conscious behaviors into daily operations.
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An acceleration bench is a critical tool used to test the stability and performance of load units under simulated transport conditions. By replicating the forces experienced during vehicle acceleration, braking and cornering, it evaluates how well loads withstand dynamic stresses.
The acceleration bench is designed to measure the resilience and security of load units, ensuring they remain intact and stable throughout transit. Testing on an acceleration bench is essential for compliance with the EUMOS 40509 standards, which sets strict requirements for the safe transport of goods. This advanced equipment provides precise data to optimise packaging, improve load securing methods, and enhance overall safety in logistics operations.
Our tilt vibration bench is a key tool for analysing pallet stability under real-world transport conditions. Using a precision Basler 3D camera, it detects even the smallest movements as loads are subjected to tilt and vibration forces, simulating damaged roads, steep inclines, and rough handling.
Testing to DIN 55415 standards, it helps assess the integrity of both your wrapping material and palletisation technique, identifying weak points before they lead to costly failures. Whether you’re looking to meet international shipping standards or simply improve load resilience, our tilt vibration bench delivers clear, actionable insights to strengthen your supply chain.
Simulates real-world transport stresses including inclines and road vibration
Basler 3D scanning technology captures high-precision load movement
Testing performed in line with DIN 55415 standards
Highlights weaknesses in palletisation and wrapping performance
The Technoplat 3000 is a fully automatic pallet wrapping station designed for high-volume, high-efficiency operations. Built with a heavy-duty frame and advanced technology, it ensures consistent, precise wrapping performance. With options for fixed or variable pre-stretch, it can wrap up to 35 pallets per hour with reduced material waste.
The intuitive touch screen control, featuring Cube Technology, allows easy setting adjustments for different load profiles. Integrated with the R-Connect system, it also enables real-time remote monitoring, ensuring maximum uptime and performance. Ideal for improving load stability, minimising film use, and enhancing process efficiency, the Technoplat 3000 is a vital asset for modern logistics.
Fully automatic operation with up to 35 pallets wrapped per hour.
Adjustable pre-stretch from 100% to 300% for optimal film use.
Remote monitoring and troubleshooting via R-Connect.
Heavy-duty construction ensures durability in high-demand environments.
The Robopac LP Masterplat is a low-profile turntable wrapping machine, specifically designed for easy loading and efficient pallet wrapping. With a turntable height of just 30mm, it allows for smooth access from all sides, reducing the risk of damage during loading with pallet trucks or forklifts.
Offering a 250% fixed pre-stretch option via the PGS carriage, it delivers excellent film efficiency while maintaining strong load containment. Its compact design and intuitive 3.5-inch colour display make it ideal for businesses seeking high performance without sacrificing space or usability. The LP Masterplat perfectly balances operational savings with robust wrapping performance.
Low-profile 30mm turntable for easier, safer loading from any side.
250% fixed pre-stretch for high film efficiency and cost savings.
3.5-inch colour graphic display with simple cycle programming.
Space-saving design ideal for busy warehouses and logistics centres.
The Robopac S7 Robot is a self-propelled stretch wrapping machine designed for maximum flexibility and efficiency. Capable of wrapping loads of virtually any size or shape, it combines brushless motor technology with Cube Technology for precise film placement and exceptional load containment. Its lithium battery option offers one of the lowest energy consumptions on the market, while the intuitive touchscreen control panel allows operators to create and manage multiple wrapping programmes easily.
Perfect for high-mix, dynamic environments, the S7 Robot delivers outstanding performance, mobility, and sustainability – ensuring every load is wrapped securely, efficiently, and with minimal film waste.
Self-propelled design wraps loads of any shape or size with ease.
Cube Technology ensures optimal film use and superior load stability.
Intuitive touchscreen control with programmable wrapping cycles.
Optional lithium battery offers low energy consumption and extended runtime.
The ESTL FEF-200 is a portable film force measurement device designed to accurately measure the containment forces applied by stretch wrap on pallet corners. Mounted directly onto the pallet before wrapping, the system uses up to 10 load cells to measure forces independently in both X and Y directions at multiple heights.
The data is captured in real time and processed via user-friendly software, creating detailed force profiles. By exposing hidden weak points or over-compression risks, the FEF-200 enables fine-tuning of wrap settings, optimising load security while preventing product damage and maintaining compliance with EU load stability standards.
Measures real-time stretch film forces at multiple heights and directions.
Helps optimise wrap settings to improve pallet security and prevent damage.
Portable and easy to set up across different pallet types and loads.
Generates detailed force profiles for analysis, reporting, and certification.