At President Container Group (PCG), we help companies ship smarter by designing corrugated packaging that fits products perfectly, maximizes pallet space, and reduces warehouse clutter.

Too often, businesses are unknowingly paying to ship air. An oversized box might seem harmless, but across pallets, trucks, and storage racks, those extra inches add up to wasted space, higher freight bills, and inefficient warehousing.

That’s where PCG comes in. With engineered corrugated solutions, we right-size packaging for strength, stackability, and efficiency—so you save space on the truck, in your warehouse, and on your budget.

 

Why Right-Sized Corrugated Matters

At its core, pallet optimization is about getting the most product on a pallet safely and efficiently. It’s about maximizing space, stability, and savings. 

A well-optimized pallet:

• Uses every inch of space without overhang or voids
  
• Protects your product from damage in transit
  
• Reduces your freight class (and cost)
• Keeps your loading dock running smoothly
  

Bad pallet planning? That’s when you start seeing crushed corners, shifting loads, and trucks shipping half-empty because the boxes don’t stack cleanly.

 

How Box Dimensions Directly Impact Freight Costs

Freight carriers today often charge by dimensional weight (or DIM weight). That means if your box is oversized for what it’s holding, you could be paying more than you need to.

Let’s say you’re shipping lightweight apparel in a box that’s too tall “just in case” it needs room for extras. That extra two inches? Multiply that by 50 boxes per shipment and you’ve got a pallet that just turned into two. And now you’re paying to ship air. 

Here’s a quick example:

• Original box: 16” x 12” x 10”
  
• Optimized box: 14” x 10” x 8”
  
• Savings: 18% reduction in pallet count per month, which added up to $6,800/month in reduced freight charges.

And that’s not including the downstream savings from fewer damaged goods due to tighter, more secure stacking.

 

How PCG Helps with Pallet Optimization

At President Container Group, we don’t just put logos on boxes and call it a day. We engineer packaging for real-world performance, from loading dock to delivery.

Here’s what pallet optimization looks like with us:

• CAD packaging design to test load efficiency on standard 48×40 pallets
  
• Custom corrugated boxes designed for strength, stackability, and product protection
  
• Simulation testing to ensure boxes hold up through transit, stacking, and handling
  

And because we’re vertically integrated, producing everything from the corrugated sheets to final assembly, our team can tweak, test, and deliver high-performance boxes with speed.

 

Quick Pallet Optimization Checklist

Want to know if your current setup needs a second look? Here’s a rapid-fire checklist to run: 

• Are your pallets leaving your dock with voids or overhang? 
• Do boxes shift or crush in transit?
• Are you paying for oversized packaging just to be “safe”?
• Are damaged shipments or freight reclasses cutting into margins?
• Could you consolidate multiple box SKUs into fewer optimized sizes?

Even one “yes” means there’s room to improve—and we’re here to help.

 

Ready to Ship Smarter?

You don’t have to be a packaging engineer to know when something’s not working. But with the right partner, you can get a solution that works better, ships smarter, and saves money every step of the way.

At President Container Group, we think about the box—so your business can thrive outside of it. Connect with a packaging specialist to identify savings and improve how your product ships.