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One of the biggest challenges logistics teams face is cargo damage, which is the physical harm, deterioration or loss of goods during storage, handling or transportation. Often, the problem occurs during handling, especially loading and unloading, and damages businesses by inflicting extra costs and creating delays. Their reputation also suffers. Research shows that physical handling damage accounts for approximately 25% of all cargo damage incidents, making loading and unloading one of the most critical stages in the logistics process.

Solutions such as Rollerbed systems can solve this issue. Below, we’ll look at the different types and causes of cargo damage, how to prevent damage and the role Rollerbed systems play in this.

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types of cargo damage

Cargo can experience several types of damage:

  • Physical damage: cracks, crushed packaging and dents;
  • Water and moisture damage: condensation, leaks, mould or exposure to rain;
  • Refrigerated Trailer (Reefer) damage: electrical faults, incorrect settings or prolonged delays can damage food or other temperature-sensitive goods;
  • Handling damage: rough forklifting handling, incorrect stacking and other damage from handling;
  • Transportation damage: cargo shifts during transportation and becomes damaged.
Van Loading (1)

Why minimising cargo damage is important

Minimising cargo damage is important because it protects businesses against the following problems:

  • Financial losses: financial penalties, insurance claims, storage fees, unexpected costs and sourcing from new suppliers;
  • Operational inefficiencies: delays and schedule disruptions that harm productivity while teams wait for new parts, for instance, plus the need to deal with returns and reship new items;
  • Customer dissatisfaction: not receiving good intact leads to complaints and demands for compensation from customers;
  • Brand damage: customers lose faith in the business, trust and loyalty diminish, and business relationships are harmed;
  • Compliance and safety risks: damaged cargo may reflect a lack of compliance with rules and regulations.

The financial impact can be massive. Industry analysis shows that cargo damage claims can average around £2,800 per incident, with some large shippers losing millions annually through damaged goods, reshipments and related costs.

what are the most common causes of cargo damage?

Although there are several causes of cargo damage, poor loading and unloading practices are especially common.

Poor Handling

  • Forklift damage: puncturing of goods through misalignment of forks, and collisions and goods slipping off forklift forks.
  • Inconsistent manual handling.
  • First/last mile risk concentration: failure to negotiate well the build-up of logistical, operational and safety risks in these crucial stages, leading to disruptions, higher costs, and customer dissatisfaction.
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Cargo shifting and poor load securing

Not securing cargo properly is another major reason for cargo damages. Cargo damage occurs in this regard for several reasons:

  • uneven weight distribution;
  • failure to cushion cargo with enough dunnage;
  • failure to secure cargo with enough lashing;
  • cargo shifting when the vehicle is in motion or braking.

According to industry data, around 65% of cargo damage claims are linked to improper packing and load securing, including poor weight distribution, inadequate bracing and cargo movement during transport.


Read Our Ulitimate Guide to the Safe Loading and Unloading of Vehicles
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Inadequate packaging and palletisation

Cargo damage can also arise due to unsuitable packaging and palletisation. Common instances include:

  • Incorrect pallet size: which causes goods to overhang;
  • use of weak packaging materials;
  • Improper stacking: tall, precarious pallets are more likely to get damaged, so a good rule of thumb is to stack wide, then tall.
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Environmental factors

Different elements of the cargo’s environment can affect the cargo’s condition, too, such as:

  • Condensation on container walls or ceilings (container rain), or on the cargo itself (‘cargo sweat’);
  • Exposure to severe weather;
  • Reefer Trailer failure: cargo decaying, thawing, bruising, contamination damage, infestation, over-ripening or discolouring during transit, due to reefer equipment damage or power failure.
Forklift Loading (3)

Equipment Limitations and Inefficiencies

Sometimes, equipment and system inefficiencies are responsible for the cargo damage. Common causes in this regard are:

  • Too much reliance on forklifts to load trailers and containers;
  • A lack of standardised loading systems;
  • Human error and variability.

how to prevent cargo damage

Packaging and pallet optimisation

  • Select the most appropriate pallet size.
  • Use strong materials that protect cargo from pressure, shock, vibration and hostile weather conditions. Shock-absorbent foam would be good for fragile goods, wooden crating for machinery and vacuum-sealed wrapping for perishables.
  • Use edge protectors to protect goods’ edges from damage caused by strapping.
Built in Rollertrack

Proper loading securing and distribution

  • Distribute weight evenly to prevent damage during transit.
  • Secure loads and stop them moving around by using load bars, strapping and dunnage bags.

Container and trailer inspection

  • Check for leaks or structural damage before loading, and that containers are properly sealed before shipping.
  • Make sure the trailer or container is clean and dry, and check for pests, before loading it with cargo. Take a look at our guide on Container Loading and Unloading Best Practices.

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Environmental controls

  • Use desiccants to absorb moisture in the air if the cargo is sealed within a climatic barrier.
  • Use reefers to transport temperature-sensitive goods.
  • Ventilate transport vessels with adequate airflow to avoid condensation.

Training and handling procedures

  • Train staff regularly so they handle goods with consistent care.
  • Use clear, correct labels and provide correct, legible documentation to guide cargo handling personnel.
Modular Rollerbed System MK4 In Reefer Trailer

Using Rollerbed Systems

  • Rollerbed systems enable fast and safe loading and unloading of goods into or out of trailers and vans.
  • Rollerbed systems consist of rise-and-fall pneumatic rollers, which rise when loading/unloading trailers and fall once the trailer is moving, to secure goods in place. This will prevent goods from arriving damaged.
  • By rolling goods to the edge of the trailer when unloading, this means forklifts do not have to enter the trailer to pick up goods, which is a common cause of product damage.

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where traditional cargo loading methods fall short

Traditional methods may support cargo loading, but they fall significantly short in several aspects.

The hidden risks in forklift-based loading

Loading with forklifts reduces heavy lifting, but it still poses the following risks that could create cargo damage:

  • impact damage
  • misalignment of forks
  • uneven loading
  • driver inability to operate the forklift correctly.
Forklift Loading Container

Inconsistent Load Positioning

  • Manually positioning loads with forklifts leaves gaps that allow loads to shift.
  • Manually positioning loads with forklifts makes it harder to distribute weight evenly and increases the potential for cargo damage and accidents.

Time Pressure vs Precision

  • Forklifts help operators load faster, but loading is less precise and entails a higher risk of cargo damage.
  • Tired personnel can make mistakes and load less precisely as their weariness increases. Read our guide on How To Reduce Product Damage When Loading.

Read More
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how rollerbed systems reduce cargo damage

Fortunately, businesses can reduce the risk of cargo damage if they use rollerbed systems.

What is a rollerbed system?

A rollerbed system is a built-in system fitted into trailers, vans or other vehicles and with rollers to transfer cargo smoothly. Businesses use them for palletised goods and unit load devices (ULDs). Loading and unloading activities are widely recognised as one of the most common points where cargo damage occurs, particularly when forklifts repeatedly enter trailers and containers during handling operations.

Eliminating forklift handling inside trailers

Rollerbed systems reduce the amount of forklift handling, which means fewer punctures and less damage on impact between the forklift and the cargo. Operators can also control the cargo’s movement easier.

Modular Rollerbed System MK24 In Reefer Trailer 5

Better load stability and positioning

Rollerbeds allow operators to plan loading better because they can align pallets and ULDs consistently. This consistent, precise loading allows personnel to secure loads better so they shift less during transit.

Reduced human error and safer operations

Rollerbeds allow operators to standardise loading process(es). Personnel can then rely on manual judgement less.

Gentle, controlled cargo movement

Rollerbeds load cargo in a smooth, controlled way, which minimises shock and vibration. This is crucial for loading fragile goods or high-value ones.

Modular Rollerbed System Powered Cargo Roller MK 21

Faster, safer loading

Rollerbed systems allow operators to load higher volumes faster and much more safely at the same time. This relieves pressure on personnel to load rapidly and eliminates cargo damage triggered by hurried loading.

Cargo securing

The rollerbeds’ pneumatic rollers, which help to move the cargo smoothly, fall beneath the floor so that the cargo doesn’t move during transit.

rollerbed systems vs traditional forklift loading

Rollerbed Systems Forklift Loading
Controlled movement Variable movement
Reduced impact damage Higher damage risk
Consistent positioning Manual positioning
Faster loading Slower loading

the key benefits of rollerbeds:

  • Consistent loading processes
  • Fewer cargo damage incidents
  • Higher throughput and greater efficiency
  • Fewer or lower claims and insurance costs
  • Fewer product losses and write-offs
  • Better return on investment (ROI), due to reduced downtime and reworking.

where rollerbed systems deliver the most value

Rollerbed systems become especially hand in certain industries and operations.

Air cargo and ULD handling

Air cargo, including ULDs, is cumbersome to handle, but rollerbeds make it much more comfortable. Personnel can load cargo precisely, without inflicting any major impact upon it.

Palletised Fragile or High-Value Goods

When loading fragile goods or high-value ones on pallets, rollerbed systems are also useful. The gentle way the rollerbed loads them reduces the risk of cargo damage during handling.

Cold chain logistics

Cold-chain Logistics are another area where rollerbed systems come into their own. Operators can load reefers faster, which minimises the goods’ exposure to unsuitable temperatures and preserves them.

rollerbed case studies

Tromp Transport Transform Trailer to Improve Air Cargo Handling Operations

Discover how Tromp Transport improved its air cargo handling operations by installing a Modular Rollerbed System: Powered Cargo Rollers into its trailers.

Read more

Joloda Hydraroll help air cargo operators maximise handling efficiencies

Find out Joloda Hydraroll helped an air cargo operator maximise their cargo handling efficiencies, whilst also improving safety in their new warehouse.

Read more

Lightening Loads Worldwide with Skyroad Logistics

See how we took a load off for Skyroad Logistics with our Modular Rollerbed System for air cargo.

Read more

Joloda Delivers a Quick and Efficient Load for Amelia Knight Cosmetics

Find out how we helped deliver a quick and efficient load for Amelia Knight cosmetics.

Read more

Rolling it in for Over 10 Years at Patinter Transport

See how Joloda Hydraroll helped create lighter loads for Patinter Transport using our Modular Rollerbed loading system.

Read more

Making every second count for Perishable Movements Ltd

Find out how we got Perishble Movements Ltd moving with our powered cargo roller system.

Read more
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reducing cargo damage starts with better loading systems

Most cargo damage happens during handling and loading, and rollerbed systems address the root causes: movement, handling and inconsistency.

Explore rollerbed solutions for your operations

We’re specialists in loading solutions, having operated in this space for more than 60 years and supported businesses and organizations in a wide variety of industries with our cargo loading equipment.

We offer several different types of rollerbed systems, which, using a ‘floor-on-floor’ concept, can be retrofitted into different vehicles to reduce cargo damage and make loading and unloading safer and more efficient. These include:

Modular Rollerbed System: Air Cargo

Modular Rollerbed System (MRS): Air Cargo: designed for handling air cargo and compatible with any standard van or trailer.

For this Modular Rollerbed System: Air Cargo project, we supplied Skyroad Logistics with a solution that helped scale their trailer loading capacity, reduce their lead time, and save them costs.

When we met Skyroad Logistics at the Munich Air Cargo Show, they were looking for a solution that would help them deal with peak demand. When they told us how difficult it was to find trucks in Australia, built to the specifications they needed, we knew we had the perfect solution.

Skyroad Logistics is a transport company providing Road Feeder Services to all the major airports in Australia. They move air cargo to and from the airports and are headquartered in Melbourne, with a subsidiary in Sydney.

Skyroad's Founder & Managing Director, Mr. P. Assel said, "The Joloda Hydraroll system creates a more efficient loading and unloading process for the customer as well as significant cost savings."


Read The Full Case Study
Joloda Hydraroll Icons Loaded Pallet

works with pallets

Joloda Icon Creation ULD

works with ULD's

Joloda Icon Creation AIRCARGO

works with air cargo pallets

Modular Rollerbed System: Block Pallets

Modular Rollerbed System (MRS): Block Pallets: designed for loading block pallets into trailers.

For this Modular Rollerbed project, we supplied Patinter with a solution that improved their safety and efficiency when loading.

Transport company Patinter, is a family owned freight road company from Portugal running since 1968. With its fleet of over 2000 vehicles it is one of the leading companies on the Iberian peninsula.

Mr Pedro Polonio, Company Director, Patinter, commented: “Loading and unloading of all ULD’s goes very smooth and quick. Besides for transporting air cargo, we see growing interest in other industries as well for such solutions."

The floor is designed for moving air cargo but has now been adapted to move standard pallets.

Modular Rollerbeds are especially favoured for refrigerated vehicles as it prevents having to cut into the expensive insulated floor to install the conventional rollerbed systems. Modular rollerbeds give flexibility and meets instant demand to cope with seasonal peaks or short term contracts.


Read The Full Case Study

Modular Rollerbed System: Vans

Modular Rollerbed System (MRS): Van: designed to make loading standard vans and small trucks easy to load.

Amelia Knight cosmetics, who supply cosmetics to Asda, Primark and many other large retailers have invested in another Modular Rollerbed System: Van, bringing further efficiencies to their deliveries.

Their cosmetic products are moved in metal containers which sit on pallets to various locations. The MRS Van system allows the heavy pallets to be easily rolled in and out of the van.

This case study explores how our MRS: Van system helped Amelia Knight cosmetics operate safer, and improved the efficiency of their operations by reducing loading and unloading times.


Read The Full Case Study

safety: autodown explained

1. brake pedal depressed

In this situation goods have been loaded into a transport vehicle and a human error has occured. The operator has not lowered the rollers after loading and the driver of the vehicle is getting ready to start transit. When the brake pedal is pressed an electrical signal is sent from to the control box.

2. raised rollertrack

The electrical signal reaches the control box and activates the system's three-way Quick Exhaust Valve (QEV). The quick exhaust valve then safely and efficiently expels air from the rollertrack modules which causes the rollers to be lowered.

3. secure load

The rollers have now been lowered and the goods in the vehicle now are not 'live'. This means that they will not move around during transit and prevents damage to the vehicle and to the products.

4. safe haulage

The push/pull levers have also entered their Autodown Reset phase. This is where the levers return to a safe position ready for the next use cycle.

Powered Cargo Rollers

Powered Cargo Rollers: an automated system designed for loading AKEs and air cargo pallets in and out of truck trailers.

By installing our Powered Cargo Rollerbed system, Tromp Transport has transformed its trailer operations to better support high-throughput air cargo handling. The solution enabled their 13.6-metre trailer to be loaded in as little as 90 seconds, significantly reducing turnaround times while improving safety by eliminating manual handling inside trailers.

As a result, Tromp Transport can handle high-value, sensitive cargo more efficiently and scale operations to meet growing air cargo demand with greater reliability.

Managing Director, Jan Tromp, stated: “It has enabled us to use standard trailers, without modification to handle all kinds of air freight with precision and make loading safer for our drivers."


Read The Full Case Study

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.

Joloda Sales Team

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speak to the experts

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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frequently asked questions (FAQ)

What are the most common reasons for cargo damage?

Cargo damage most commonly occurs due to poor handling, inadequate load securing, cargo shifting during transit, unsuitable packaging, environmental exposure, and forklift-related impacts during loading and unloading.

Damage is often caused when goods are not properly positioned, distributed evenly, or secured within a trailer, container, or cargo vehicle. Handling-related issues are particularly common because loading and unloading are among the highest-risk stages in the supply chain.

Why is minimising cargo damage important?

Minimising cargo damage is important because it helps businesses reduce financial losses, improve operational efficiency, maintain customer satisfaction, and protect their reputation. Damaged goods can result in insurance claims, product write-offs, replacement costs, delayed deliveries, and disruptions throughout the supply chain.

Is there a way to prevent or minimise damages from cargo?

Yes, cargo damage can be prevented or significantly reduced through a combination of proper packaging, secure load restraint, staff training, trailer inspections, and effective loading procedures. Businesses should ensure cargo is evenly distributed, properly secured, and protected against environmental factors such as moisture and temperature fluctuations. Loading systems such as Rollerbed systems can further minimise damage by reducing forklift handling, improving load positioning, enabling controlled cargo movement, and preventing loads from shifting during transport.

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