how to safely load freight for air shipments

• How Do You Safely Load Freight for Air Shipments?
• What is Air Freight Shipping, and What Does it Include?
• Why Safe Loading is Important in Air Shipments
• Understanding Air Cargo Regulations and Responsibilities
• How to Prepare Freight Before Air Shipment
• Unit Load Devices (ULDs) and Palletisation Best Practices
• Special Cargo Handling Considerations
• Equipment and Ground Handling Safety
• Air Freight Loading Checklist
• Handle Air Freight Safely with Our Air Cargo Handling Equipment

‘Air freight shipping’ refers to the transportation of goods by aircraft. Air freight is a specific category within air shipping that describes commercial goods transportation by dedicated cargo aircraft or freight services. It also covers logistics, costs, and air cargo transport regulations. According to IATA, airlines transport over 62 million cargo tonnes of goods a year, representing more than 33% of global trade by value

We discuss air freight in further depth in our article on the difference between air freight and air cargo.

The risks of improperly loaded air freight

Failing to load air freight correctly can have serious operational, financial and safety consequences.
 

• Load shift and aircraft balance: Cargo that is poorly secured or unevenly distributed can move during take-off, flight or landing. This can alter the aircraft's centre of gravity, affect stability and, in extreme cases, compromise flight safety.
• Damage, rejected cargo and flight delays: Inadequately packaged or secured freight is more likely to become damaged during handling or transport. Cargo that does not meet airline or regulatory requirements may also be rejected before departure, resulting in delays, additional handling costs and disruption throughout the supply chain.
• Regulatory penalties and reputational risk: Airlines, freight forwarders and cargo handlers must comply with strict international regulations governing the transport of air freight. Failure to meet these requirements can lead to financial penalties, enforcement action and damage to an organisation's reputation. Consistently following recognised loading procedures helps businesses remain compliant while maintaining customer confidence.

Key regulations every air cargo shipper and handler must know

It’s essential for all air shipping companies and air cargo handlers to know certain sets of regulations that affect the air shipment process.

• Dangerous Goods Regulations (DGR): the DGR classifies dangerous goods, sets out shipper and carrier responsibilities, and outlines requirements for packaging, handling and documentation and for working with radioactive materials.
• Live Animals Regulations (LAR): the LAR covers the transportation of animals of all kinds.
• Temperature Control Regulations (TCR): the TCRs contain all the requirements for shipping temperature-sensitive goods.
• Perishable Cargo Regulations (PCR): the PCR contains all the information and best guidance for developing processes for shipping perishable goods such as seafood and exotic houseplants.

Packaging freight for air transport

When packaging freight for air transport, logistics teams should use special equipment and follow recommended practices:

• Use double- or triple-walled boxes, and avoid re-using boxes;
• Immobilise heavy or irregular-shaped items with crates;
• Protect goods against moisture with water-resistant packaging and desiccants;
• Preserve the structural integrity of pallets with edge protectors and protect items with extra cushioning.

Common Packaging Mistakes That Delay Air Shipments

Even when the correct packaging materials are used, poor packing practices can still lead to delays, damaged cargo or rejected shipments. Some of the most common mistakes include:

• Overpacked boxes: Boxes filled beyond their intended capacity can bulge or split during handling, stacking or changes in air pressure. This increases the risk of damage to both the shipment and surrounding cargo.
• Weak tape: Using low-quality or insufficient sealing tape can cause cartons to open during transit. Heavy-duty packing tape should be applied correctly to all seams to ensure packages remain securely sealed throughout the journey.
• Unstable cartons: Cartons that are unevenly packed or have an unbalanced weight distribution are more likely to collapse or shift when stacked. Ensuring loads are stable and evenly packed helps protect goods and supports safer palletisation and ULD building.

How to build a stable ULD or pallet load

There are certain best practices to follow when building a ULD or pallet load:

• place heavy items at the bottom and lighter ones at the top;
• distribute the weight evenly on pallets;
• avoid overhanging because it weakens pallets;
• load cargo in an interlocking manner, if possible.

Securing the load for flight

When securing the load for flight, there are several ways to do so:

• cargo nets, which, if it’s not possible to interlock the cargo, should have ropes or straps under them to hold the cargo in place;
• stretch wrap, starting from the base and working upwards’
• straps;
• locks.

Perishable and temperature-sensitive cargo

• Perishable goods require temperature-controlled environments and constant monitoring.
• Shippers must always indicate whether dry ice is being used as a refrigerant (it’s considered a dangerous good).
• Active containers are best if the shipper wants to be able to plug a container into the mains to keep it cool in the event of delays, whereas passive containers maintain their internal temperature for 72 hours and are appropriate if the shipper is confident of no major delays.
• Perishable shipments must be labelled with the standard “PERISHABLE” IATA label. They should also be labelled with the ‘THIS WAY UP’ label. ULDs should have the IATA ‘PER’ label. Since perishable cargo is handled as ‘wet cargo’, correct labelling is essential.

High-value and fragile cargo

A wide range of goods come under ‘high value’ or ‘fragile, including electronics, jewellery, artwork, luxury items, automotive parts and specialist machinery. When shipping these, it’s important to consider:

• documentation: this includes commercial invoices, certificates of authenticity and global trade export licences;
• chain of custody: this audit trail of the shipment ensures security and accountability as it passes from one team to another until it reaches its destination;
• stacking: fragile items must have a ‘Do Not Stack’ label on them. This is important because personnel can damage non-stackable pallets, the load can incur extra costs and must also be treated as if it takes up more space than it does.

How the right air cargo equipment improves safety and efficiency

Modern air cargo handling solutions play an important role in improving safety and efficiency by:

• enabling cargo handling teams to build up ULDs faster and break them down more quickly;
• reducing damage and minimising errors;
• making it easier to comply with weight regulations and balance.

In air cargo handling, baggage and cargo handlers are at risk of musculoskeletal disorders, so using mechanical handling equipment and reducing manual handling are important safety measures

• Pre-Build ULD Inspection: Check the empty pallet/container, nets, straps, and corner locks for damage or expiration tags (per IATA ULDR).
• Dangerous Goods (DG) Acceptance: Verify Shipper's Declaration, UN dangerous goods labels, package integrity, and compatibility before staging.
• Weight & Dimension Verification: Check individual cargo piece weights and dimensions against the Air Waybill (AWB) limits.
• Cargo Build-up & Load Distribution: Stagger heavy packages at the base and distribute weight evenly to maintain the ULD center of gravity.
• Contour Verification: Ensure the load profile matches aircraft envelope dimensions (lower deck vs. main deck).
• Cargo Securing: Apply pallet nets, tie-down straps, or lock container doors securely.
• Final Weighing & Tagging: Weigh the fully built ULD on a calibrated scale and attach the mandatory ULD tag showing gross weight.
• Final Pre-Load Inspection: Perform a visual check for net tension, latch security, and label visibility before loading aboard the aircraft.

Expert Insight

Proper load planning begins before freight reaches the aircraft. In our experience supplying air cargo handling systems to airports and cargo hubs worldwide, the safest operations combine compliant packaging, well-trained handling teams and specialist equipment designed specifically for ULD movement.

Key Takeaways

• Safe air freight loading starts before cargo reaches the aircraft: Proper packaging, pallet preparation and ULD inspections help prevent damage, delays and compliance issues.
• Correct weight distribution is essential: Evenly balanced loads reduce the risk of cargo shifting during take-off, flight and landing, helping maintain aircraft stability and safety.
• Compliance with international regulations is critical: Following IATA and ICAO guidance, alongside regulations covering dangerous goods, perishables and live animals, helps ensure shipments can travel safely and legally.
• ULDs must be built and secured correctly: Stable palletisation, appropriate restraints and approved loading methods minimise the risk of damaged cargo and rejected shipments.
• Different cargo types require different handling procedures: Dangerous goods, lithium batteries, temperature-sensitive products and high-value freight each have specific packaging, documentation and handling requirements.
• Specialist air cargo handling equipment improves both safety and efficiency: Equipment such as Powered Rollerbeds, Castor Decks, Dolly Docks, Build Stations and Slave Pallets reduces manual handling, speeds up ULD movement and helps maintain safe loading practices throughout the operation.

Loading aircraft safely is essential to reduce the risk of injury and ensure the cargo arrives intact. Our air freight services make air shipping safer and more efficient. Air freight loading equipment like the powered rollerbed does the heavy lifting, and other air cargo handling solutions make pallet building and transfer more straightforward.

Looking to support your air shipping with our cargo handling equipment?

Email us at hello@joloda.com or message us via our contact form to start the ball rolling. Our experts will discuss and evaluate your site to decide the best solution, and our engineers will carry out any installation necessary so you can boost operations in as little time as possible.