# Dispatch # Palletisation Rules # Palletisation Rules – Dispatch SOP This page defines the business rules used to determine when an order should be dispatched on a pallet rather than via standard parcel packaging. These rules are applied after `BoxPacker` has calculated the optimal packages for the order. ## 1. Purpose To ensure consistency, cost-efficiency, and safe transport of large or high-value orders by automatically determining when palletisation is required. ## 2. Overview All orders are first processed through the **DeliveryCalculator** and **BoxPacker** to find the most efficient fit using available packaging (boxes, wrappers, tubes, or custom packages). The rules below are then applied to determine whether pallet delivery is required or recommended. ## 3. Palletisation Decision Rules

Rule 1 – Mandatory Pallet (10×5 Jobs) Any product marked as “10×5” or exceeding **3050 mm width** or **1520 mm height** must always be shipped on a pallet. *Reason:* Size exceeds courier handling limits.

Rule 2 – High Value Orders (£1000+) Any order with a total value of **£1000 or more** should be palletised by default. *Reason:* Reduces risk of damage or loss for high-value shipments.

Rule 3 – Quantity Threshold If the order contains **6 or more packages** (boxes, tubes, or wrappers), pallet delivery is preferred. *Reason:* More efficient and secure bulk transport.

Rule 4 – Custom Package Threshold If the order includes **4 or more custom packages**, pallet delivery is recommended. *Reason:* Custom packages are typically larger or irregular; combining them increases handling risk.

Rule 5 – Large Format Escalation If any single package exceeds **1200 mm width** and **800 mm height**, a pallet should be used. *Reason:* Size approaches courier limits; palletisation ensures stability and protection.

Rule 6 – Volume-Based Recommendation If total combined package volume exceeds roughly **70% of the smallest pallet volume** (0.67 m³), escalate to pallet delivery. *Reason:* Predictive optimisation to avoid multiple parcel shipments.

## 4. Pallet Type Selection

Condition	Pallet Type
Width ≤ 1200 mm and Height ≤ 800 mm	Euro Pallet – 800
Width ≤ 1220 mm and Height ≤ 1000 mm	4×4 Pallet
Width ≤ 2440 mm and Height ≤ 1220 mm	8×4 Pallet
Width > 2440 mm or Height > 1500 mm	10×5 Pallet

## 5. Decision Summary

Trigger	Action
Contains 10×5 item	Mandatory pallet (10×5 Pallet)
Order value ≥ £1000	Use pallet
≥ 6 packages total	Prefer pallet
≥ 4 custom packages	Prefer pallet
Any package > 1200×800 mm	Use pallet (choose based on size)
Volume > 70% of smallest pallet	Recommend pallet

**Note:** These palletisation rules are applied automatically within the `DispatchPolicyEvaluator` service after `BoxPacker` has generated the list of packages. The system records the reasoning for each pallet decision for auditing and optimisation.

# Packaging

Package Name	Dimensions	Internal Dimensions	Courier	Supplier	Cost
A3 Book Wrapper	470x350x70	420x300x50	Fedex	Internal	0.55
Box - Small	305x229x229		Fedex	Antalis	1.10
Tube - Small	750x150x150		Fedex	Antalis	0.87
Tube - Medium	950x150x150		Fedex	Antalis	1.27
Tube - Large	1100x150x150		Fedex	Antalis	1.41
Tube - Double Small	1350x150x150		Fedex	Antalis	1.74
Tube - Double Medium	1750x150x150		Fedex	Antalis	2.54
Box - Medium	457x305x305		Fedex	Antalis	2.33
A1 - Wrapper	950x750x70	860x630x50	Fedex	Internal	1.80
Tube - Double Large	2000x150x150		DX	Antalis	2.82
Tube - Full Length	3200x150x150		DX	Antalis	4.23
A0 - Wrapper	1400x950x70	1200x900x50	DX	Internal	2.50
Tube Oversized	2500x200x200		DX	Repurposed Packaging
Box - Large	610x457x457		Fedex	Antalis	1.35
Cardboard Sheet	1600x2150		DX	Antalis	2.03