Maximizing volume of loaded boxes

In recent years, we have accumulated considerable experience working with pulp and paper mills to develop optimal loading schemes for their products. Therefore, the algorithm described below is suitable for packaging bales of cardboard and for similar products standardized in size.

Basic loading requirements:

• Maximize the volume of products in the trailer
• The same type of cargo is placed, preferably, next to one another and on top of each other
• Follow the order of loading products for different customers
• Axle load control to comply with important seasonal restrictions
• Generally, the total length of the loaded part is minimized
• Ability to calculate the loading of an already partially filled trailer

Cargo parameters

All cargoes should be optionally packed together incrementally in height, do not set tiers and layer constraints. Usually bales cannot be turned over, so you need to set the appropriate restriction in the parameters. Example for packs of 2 and 3 bales in the figure below.

The height of the lower pallet can be taken into account by adding it to the height of the packed load. In this case, the height increment corresponds to the height of the bale, if the pallet is not placed between them.
Before starting the calculation, the algorithm generates the maximum number of full packs based on the height of the truck body. Residues, if any, form an incomplete pack. Then the arrangement of the obtained “columns” in the body is optimized.

Algorithm parameters

Calculation mode – “Balance” – “No Template”

The balancing algorithm is “Experimental”, Iterations – 200-300, Support area – 60-90

Usually, loading does not take more than 20-30 seconds.

Accounting for manual loading. In rare cases, the program may not find the optimal solution. If so, there is a mechanism for saving manually adjusted schemes to the list of approved loading schemes (folder “.. \ Data \ Save”).Then, in the future before calculating a similar loading, the program will search among the approved schemes and return a suitable previously saved result.
A partial-filled body can be additionally loaded using the corresponding button when setting the actual cargo configuration or limiting the filled body in length.

Analyzing the results, the program facilitated an increase in the volume of transported products by 4-6% in every third loading. In addition, it reduced the time for manual preparation of loading schemes several-fold.

Examples of increasing utilization of standard orders

Initial version                                                                     4 bales loaded

Initial version                                                                     2 bales loaded

Based on the results of loading, a report containing loading the scheme can be exported. The program has the functionality to customize its elements. It is convenient to display “From the bottom” step-by-step loading schemes for this type of loading. Bales standing

Based on the results of several years of joint work on the implementation of the program and the development of the algorithm for PCBK Group, top-tier pulp and paper company in Russia, we received positive feedback from the management of the company.
Conclusion:
According to the feedback of our users, automated calculation of the loading scheme in TruckLoader enabled them to load 4-6% more products in every third vehicle.
Below is the operation of this algorithm in an automated mode at PCBK.