Pallets, KLTs, mesh boxes, or reusable containers rarely go missing all at once in companies. Most often, the loss occurs gradually. A pallet is shipped out with a delivery but is not properly recorded as returned. A reusable container is left with the customer. A damaged mesh box is taken out of circulation without the process being documented. In practice, these discrepancies quickly add up to a cost and organizational problem. The situation becomes particularly critical when companies lack a reliable overview of where their loading equipment is located, who is responsible for it, and which returns are long overdue. Digital load carrier management makes movements traceable, provides transparency regarding inventory, and helps companies identify losses early on, rather than reacting only when inventory counts or bottlenecks occur.

More Parties Involved, Higher Losses

Losses of loading equipment often occur when multiple parties are involved in a process. Warehouses, shipping, production, customers, suppliers, retail locations, freight forwarders, and external service providers all work together—but the movements of loading equipment are not always accurately documented. If pallets and containers are tracked only via paper lists, Excel files, or not at all, discrepancies quickly arise between the actual inventory and the inventory expected in the system.

The direct replacement cost of a pallet or container is only part of the problem. In many companies, there are also hidden costs that go largely unnoticed in day-to-day operations. Missing loading equipment must be replaced, re-rented, or procured on short notice. At the same time, this creates internal administrative work: employees search for delivery slips, cross-check Excel lists, follow up with customers, or resolve outstanding returns with transportation service providers. The situation becomes even more problematic when there aren’t enough loading units available for production, order picking, or shipping. Damaged or late-returned containers also lead to additional work.

Overview Through Digitized Container Management

Cosys Container Management helps companies digitally record, track, and analyze pallets, containers, and other loading equipment. Movements are documented as part of the process—for example, using a mobile data collection device or a smartphone. The recorded data is consolidated in Cosys WebDesk.

Companies gain a centralized view of inventory levels, movements, receipts and issuances, stock transfers, returns, damage, and open transactions. The dashboard serves as the control center for load carrier management. An important feature in Cosys WebDesk is the analysis of overdue load carriers. It shows which load carriers are still in circulation and for which returns defined deadlines have been exceeded.

The life cycle of loading equipment can be better illustrated

Cosys WebDesk also allows companies to analyze the lifecycle of individual loading units. Companies can see how long containers remain in circulation, how often they are returned, and where problems occur. Damaged loading units not only incur costs but also provide important insights into weaknesses in the process. If damage is systematically tracked, companies can identify whether certain locations, transport routes, or handling processes are particularly prone to damage.

In addition to tracking existing loading equipment, planning also plays an important role. Cosys offers forecasting features that enable companies to better estimate their future needs for pallets, containers, or other loading equipment.