Updated 17th November 2025

Load a truck or trailer incorrectly and you could cause a serious accident. It’s a responsible job, and you can’t just load a truck any way that suits you. You have to consider how the weight of the load might affect the vehicle once it’s in transit, plus several other factors so that you do so safely.

Below we provide you with a series of tips to help you transfer your cargo to your truck or trailer appropriately. Before going into the tips themselves, we discuss some fundamental terms that, if you’re responsible for loading a truck or trailer, you should know.

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essential terms you should know

Working in logistics requires special training, and any worker operating in a warehouse or other logistics facility, should know certain terms.

We’ve picked out some of the most important ones any logistics worker who considers themselves a professional should be able to understand and, if asked, be able to explain:

Cube utilisation

his is very straightforward. ‘Cube utilisation’ is the percentage of storage space being used, and it can also refer to how much a truck is using of its storage capacity when it sets out on an outbound journey. If an area is completely full with the product, the cube utilisation is 100%.

If a warehouse or other storage facility has a low cube utilisation, it could mean the warehouse is using lots of partial pallets. This provides scope to consolidate pallets and free up inventory space for more stock.

Turned Trailer Loading Pallet Pattern

Palletised Loads

Simply expressed, a 'palletised load' is a group of items that the operator has consolidated into a single unit on a pallet. This can improve efficiency.

Turned Loading

'Turned loading' is a loading method in which, when packing the truck, the professionals place the four-way pallets sideways with the stringers perpendicular to the back wall. The method enables the professionals to lay the average 40 x 48-inch pallets side by side in the trailer.

This is a superb choice for longer, domestic shipments because it offers high cube utilisation and protects the goods from pallet shifting more than standard loading. Note, however, that although goods will experience less damage during transit, turned loading requires more labour.

Straight Trailer Loading Pallet Pattern

Straight Loading

Straight loading is a method of loading a trailer in which the operator has to use two-way pallets, (such as euro pallets, EPAL euro pallets, plastic pallets or wooden pallets) and load them in the direction of the pallet stringers. Generally, the approach allows the loading of average 40 x 48-inch pallets two across with space between the pallets and along the walls.

Straight loading is a fast way to load a truck and is good for local and regional shipments. However, the space between the pallets and the walls leaves the loads more open to pallet shifting during transit, so there is more chance of the goods experiencing some damage during the journey.

To prevent the pallets from shifting around, you’d need some sort of void fill, such as a Dunnage air bag, to help keep them in place.

Pinwheeled Pallet Pattern Trailer Loading

Pinwheeling

'Pinwheeling' is the third way to load a truck or trailer. In this method, the person loading the truck alternates the direction of every other pallet, which creates a combination of straight and turned pallets.

Pinwheeling uses the space inside the trailer more fully when you can’t accommodate two pallets side by side and is handy for loading small containers.

It’s a useful way to pack loads of different orientations, especially tall or unstable loads because you can create extra stability when locking them together. However, the cube utilisation is lower, and the method is slower, reducing productivity.

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essential truck loading tips

Ensure the Truck is Braked and Stabilised

A vehicle should absolutely never be allowed to move while workers are loading or unloading them, or are moving around them. To prevent unsafe movements, drivers should apply the brakes and ensure they’ve implemented the stabilisers in the correct position.

Be aware that disconnecting the emergency line on most trailers doesn’t apply the parking brake.

Ensure the Truck is Parked on Firm, Level Ground

It’s always best to ensure you’ve parked the vehicle on firm, level ground. There should be no potholes or debris on it. This is to keep the vehicle stable.

Obtain the Keys From the Driver

This is a simple safety precaution to stop the driver pulling away while workers are still loading or unloading the trailer. If you’re loading or unloading from within a stepped loading dock, this is especially important. Hold on to the keys until the end of the loading or unloading operation.

Start Loading at The Headboard

This is the correct way to set about loading your truck or flatbed trailer. Be careful if the trailer is detached from the tractor unit: you’ll have to think about the amount of weight you’re putting at the front. 

The overhang from the trailer legs to the headboard is long, and if you put too much weight on the front, you could cause the trailer to tip up because it’s unsupported. This is especially the case if you’re double stacking loads.

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Support the Front of the Trailer in Stepped Docks

If you’re loading a trailer or a container lorry, are doing so from within a stepped dock and the tractor unit is detached from the trailer, support the front of the trailer.

Don’t drive onto the trailer in a forklift truck. Otherwise, the combined weight of the forklift truck and the load could tip the unsupported trailer.

Secure the Load

Securing loads is absolutely critical. Don’t rely on sheer gravity alone to secure them. There are several different techniques to secure loads before they leave the warehouse or loading bay. Cleats, straps, blocking, load bars, braces, webbing and separators are all tools that can help you keep the load(s) in place. Stretch wraps, shrink wraps, edge protectors and banding are further measures you can employ.

Train Employees

Human error is one of the main causes of injury in loading docks and other areas of logistics facilities, and safety starts with the employees. If you’re an employer, train your staff on:

  • Ergonomic movements, to prevent chronic or acute injury;
  • The way to secure cargo when loading;
  • Safe removal of secured cargo when unloading the truck;
  • Use of the warehouse management system;
  • Equipment and communication;
  • Safety protocols.
Logistic company employees in a warehouse planning process improvements to increase operational efficiency and reduce costs

Be Aware of Common Mistakes

As part of the employee’s training, you should make them aware of common mistakes during loading or unloading that cause inefficiencies in the processes. Wastage of space in the trailer, inefficient loading practices and non-ergonomic movements are three common errors.

When loading a trailer, an employee should keep items close to their body and lift with the legs. If they have to lift anything more than 50 lbs (22.6 kilos), they should ask for help or use some machinery.

Minimise warehouse travel wherever possible

The fewer employees have to travel around the warehouse, the better for the efficiency of your loading and unloading processes, not to mention the lesser the potential for accidents. Cross-docking is one strategy that can minimise the number of distance employees or forklift trucks has to travel around the warehouse.

Be aware that although this strategy makes the employees available for loading and unloading of goods as they arrive, it may not be suitable for all warehouses.

Mount lights

Good lighting is essential. You don’t want your employees performing their duties in dark trailers and poorly lit loading bays. Ideally, you should connect your lights to a centralised communication system.

he lights can communicate when a truck is safely locked when a truck is coming in, when it’s safe to unload and when it’s safe for the driver to pull away.

Use Dock Levellers

Dock levellers bridge the gap between a trailer and a loading dock when they’re at different heights, ensuring the goods flow smoothly between the trailer and the loading bay.

This is important because loads can add or subtract weight to the trailer, causing the trailer itself to shift in height. Using hydraulic levellers is safer because they operate with the push of a button, whereas mechanical levellers force workers to bend down to pull the leveller up.

Conveyor Maintenance (1)

Devise and Implement a Regular Maintenance Routine

Clutter and obstructions invite trips, slips, falls and other accidents that can injure workers seriously. Form and follow a daily plan to keep the loading dock safe to work in.

There should be no crates, wires, chains, bins or cables where workers have to walk, and you should conduct regular maintenance and inspect equipment regularly for malfunctions. Workers and supervisors should have a checklist to follow before and after each loading or unloading operation.

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tips for loading pallets

Consideration of the Weight

Before loading, ask, ‘What is the weight of each unit?’ and ‘Will it overload the capacity of the truck?’ You have to be able to load as much as possible but still keep in line with the cubic capacity of the vehicle you’re loading.

Distribute the Weight Evenly

The amount of weight isn’t the only thing to consider; you should also be loading the truck or trailer as evenly as possible. Not doing so can make the vehicle unstable on the road or overload the axles.

Use Extended Forks

This is optional. If you add an extended carriage to a forklift that has two pairs of forks, you can load two pallets at a time. You should only do this if the forklift truck has the necessary load capacity and you can fit on the appropriate add-on.


Read Our Ultimate Guide on How to Load Pallets Faster
Ultimate Guide Safe Loading And Unloading Of Vehicles 01

the ultimate guide to safe loading and unloading of vehicles

The tips above will help you to load your truck(s) or trailer(s) in line with health and safety guidance. You can find even more advice in our Ultimate Guide to Safe Loading and Unloading of Vehicles, where we also discuss load securing, the role of employers and employees, addressing chemicals, loading and unloading hazards and more.


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Contact us today for a consultation session with a member of our Systems team.

During the consultation, a Joloda Hydraroll Group Systems Expert will speak with you about your business' current logistics operations, plans and goals. 

We have over 60+ years of experience providing cutting-edge technological solutions to the logistics industry and have helped countless companies around the world lighten their load.  


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loading your trailer safely with Joloda Hydraroll loading systems

We exist to help you lighten your load. Not only that, but we wish for you to do this safely, which is why we’ve developed several automatic and manual solutions to achieve this.

You can load your vehicles safely without sacrificing efficiency. Actually, instead of sacrificing efficiency, you can step it up.

Loading Solutions

Choose one of our loading solutions and you’ll be selecting a simple, cost-efficient way to safely load and unload your vehicles. For trailer loading we offer two main 'manual' solutions: the 'Skate and Track', ideal for pallets and paper reels, and the 'Rollerbed' systems, which exist in different variations.


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Paper Reel Loading with Skate and Track System (1)

Skate & Track Loading System

We’ve designed the Skate & Track Loading System especially for trucks and light vehicles. The skate and track increase safety through the use of a sunken track into which the manufacturers have built roller skates, removing the need for forklift trucks to enter the trailer.

The skates can handle up to 3.5 tonnes and are good for moving pallets, machinery, drums and other heavy goods. Just pull the handle to lift the load, and then you can push or pull the goods to wherever you need to transfer them. More good news: maintenance is minimal, and the skate and track system has a self-cleaning system which facilitates this even more.


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Built in Rollertrack

Rollerbed Loading Systems

Our Rollerbed Loading Systems, made up of rollertrack modules, reduce the number of workers necessary to load and unload vehicles.

Thanks to the pneumatic rise-and-fall floor of the system, they’ll be able to shift a wide range of pallets and containers. As mentioned above, we offer multiple variations. These are:

The Built-in Rollerbed

A customisable system which you can integrate into the existing floor of vans, trucks and trailers. Only one or two people need to conduct the loading or unloading, which they can do extremely safely, and the goods will be safe during their journey to their drop-off or collection point. It’s easy to maintain as well.


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our rollerbed systems works with

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wooden pallets

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air cargo ULD's

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metal pallets

MRS Block Pallets

Modular Rollerbed System (MRS)

Our Modular Rollerbed Systems (MRS) can be set out on the floor of your vehicle and do not require any permanent amendments to it. This system provides the same benefits as the built-in rollerbed, is pre-built, modular, and serves as a safe, convenient, retrofit solution.

System maintenance is also easy. The Modular Rollerbed System comes in a range of applications. For trailer applications there are variations for handling Block Pallets or Air Cargo. Alternative applications are for Vans, and Warehouse Floors (mainly for handling air cargo).


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Powered Cargo Rollers

Our Powered Cargo Rollers are an automated variation of our Rollerbed systems. The system is primarily used for loading and unloading air cargo and is ideal for road feeder services (RFS) or road transportation. The automated rollers mean that employees aren't required to enter the trailer when loading or unloading goods, drastically improving safety for employees and cargo.

The system comes in both a built-in or modular variation.


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a safety first solution

The Modular Rollerbed System with Powered Cargo Roller System prioritises safety in several aspects, offering enhanced protection for both operators and the cargo being transported.

No Pushing

Firstly, the powered nature of the system eliminates the reliance on physical pushing from employees. This means that operators no longer need to exert physical force to load or unload cargo manually, reducing the risk of strains, injuries, and musculoskeletal issues caused by repetitive manual labour.

Controlled Loading

Secondly, by providing a powered solution, the system ensures that cargo is loaded and unloaded in a controlled manner, reducing the chances of mishaps, or damage caused by uncontrolled movements. Also, the system prevents operators from misusing the system meaning the loading process is conducted safely.

No Trapping or Tripping

Finally, operators do not need to enter the truck during the loading and unloading process, which eliminates the risk of operators from being in front of the pallet, which prevents accidents, trip hazards, falls, or being struck by moving cargo.

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Increase customer satisfaction

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enable orders to be fulfilled quicker

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Improve operational efficiencies

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Increased productivity

automated loading solutions

Your other option is to choose one of our Automated Loading Solutions. You’ll be able to transfer the same number of pallets but reduce the number of people, trucks or forklift trucks you need to do it, improving the safety if your operations.

The use of automated loading saves internal space and shortens driver waiting times, so you can get more goods out on the road sooner. We provide three main options


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Moving Floor

The Moving Floor System is ideal for loading pallets of any size. It’s safe, simple to use and efficient. All you have to do is set up the floor in your vehicle, place your load onto the coils and then watch them transport the load into your truck.

If the load is already inside the truck, you can sit back and let them transfer them to the loading dock, ready for unloading. What could be easier?

This system's best suited to businesses with high-volume logistics shuttle cases, and small fleets of dedicated trailers


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Slipchain, Pallets

Slipchain

The Slipchain Loading System allows you to conduct high volumes of loading and unloading in complete safety. We can help you improve the safety of the working environment, by ensuring the trailer is locked in place with the use of an additional fifth wheel located at the back of the loading dock.

Then, a mere push of a button will get things moving. The platform tracks rise up and transfer the load from the Slipchain dock and into your trailer, or from it, as you wish. It’s a durable, modular system and requires minimal changes to your existing structures or trailer. The Slipchain connects to production line conveyors effortlessly or you can incorporate it into your building.

This system's designed for all customers that have high-volume logistics shuttle cases with a small fleet of dedicated trailers.


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Trailerskate (10)

Trailerskate

The Trailerskate System serves many different businesses reliably, but it’s especially exceptional useful when it comes to operators in the fast-moving consumer goods (FMCG), packing, food and drinks industries. At the same time as being able to operate more safely, operators can enjoy much higher levels of productivity and efficiency, due to their use of the Trailerskate.

The system skates sit on a loading dock that connects to the trailer floor and will help you cope with high volumes of loading and unloading easily. The system collects pallets or other loads and transfers them to the skates, either moving them from the trailer or to it as you wish.

Loading and unloading is extremely safe with this system, as it is with our other systems, and will serve a high-volume logistics business that has a large fleet well.

This system's designed for businesses with a high-volume logistics shuttle case with a larger fleet of trailers


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EFFICIENT LOADING

Automatic loading in under 5 minutes, with minimal modifications required.

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NO TIME WASTED

Fast efficient loading, 26 pallets in 2 minutes.

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SAFER LOADING

Reduces use of forklifts in and around loading bays, fail safe manual skate back up system.

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Top 5 Loading And Unloading Challenges Block

the top 5 loading and unloading challenges

The transport sector has experienced tremendous growth over recent times, with online retailing and home deliveries a key factor. From retail to food, DIY to home furnishings, there are few industries that haven’t struggled to keep up with demand from consumers and distributors alike. Learn about The Top Five Loading and Unloading Challenges to think about…


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frequently asked questions (FAQ)

What is The Correct Way to Load a Truck Safely?

The safest way to load a truck is to distribute weight evenly, secure every load, and follow an approved loading plan that reduces manual handling risks. The heaviest items should sit against the bulkhead, with load-securing equipment used to prevent shifting during transport.

Using mechanical or Automated Loading Systems can significantly reduce risk by creating a controlled, repeatable loading environment and minimising reliance on manual labour or forklifts.

How Should Pallets be Loaded on a Truck for Maximum Stability?

Pallets should be loaded in straight rows, turned loading or pinwheeled depending on pallet size, vehicle width, and stability requirements. Heavy or dense pallets should be placed at the front, and gaps between pallets should be eliminated to reduce movement.

Automated loading systems ensure pallets are loaded in a consistent pattern, preventing uneven placement, reducing handling errors, and improving pallet-to-pallet contact. which are key factors in maintaining load stability.

What is The 60/40 Rule When Loading a Truck or Trailer?

The 60/40 rule recommends loading 60% of the weight toward the front of the trailer and 40% toward the rear. This creates a forward centre of gravity, improving steering, braking efficiency, and stability under emergency manoeuvres.

Loading systems naturally encourage correct weight distribution because they load pallets in controlled sequences, following the same pattern every time. This improves compliance and helps standardise safe loading practice across teams.

What are the most common mistakes to avoid when loading a truck?

Common errors include uneven weight distribution, unsecured loads, leaving gaps between items, relying on damaged pallets, and excessive manual handling. Other risks arise from forklift misuse, poor visibility, or time pressure during loading.

Automated trailer loading solutions reduce these issues by guiding operators through a structured, mechanical loading process, lowering the chance of human error and removing unnecessary forklift movements inside the trailer.

What UK Regulations Apply to Safe Truck Loading and Unloading?

In the UK, safe loading is governed by HSE guidance, PUWER, LOLER, and relevant workplace transport regulations. Operators must demonstrate competence, secure all loads to prevent movement, maintain safe loading areas, and use suitable equipment that is properly maintained.

Automated Loading Systems support compliance by reducing manual handling exposure, limiting forklift interaction with pedestrians, and creating structured, repeatable processes that align with HSE best practices.

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