Loadhog® Pallet System.

Innovate pallet management device.

About Loadhog.

Loadhog is a UK manufacturing company specialising in products that solve handling and logistics problems within the supply chain for a wide range of industries.

One area the company wanted to innovate in was pallet lids. Traditionally, load-on pallets were wrapped in film, capped with plywood and bound using disposable strapping, all of which ends up being thrown away. It’s proposed solution was to create a reusable means of securing a load to a pallet, and invited Optima to help it to achieve this aim.


Optima created a number of potential mechanical solutions for the securing mechanism, and used analysis to digitally prototype the potential solutions. The result was a robust plastic injection moulded lid incorporating retractable straps with an integrated tensioning mechanism, allowing fast and waste-free pallet security. The revolutionary lid could be made in various sizes, bespoke to the customer’s needs. The team utilised FEA and physical prototypes to perfect the mechanism design, and ensure it was robust enough to withstand life in the demanding delivery and logistics environment.

The Loadhog Lid could be provided with branded straps, was waterproof, nestable when empty, and could be used with security seals for tamper evidencing.

Further benefits of the Loadhog Pallet Lid system include:

No one trip packaging, meaning a much more sustainable logistics approach.
Unrivalled pallet stability and security
2 minutes labour saving per pallet on application
Dedicated platform for secure double stacking

The product was successfully transferred into mass manufacture and was launched
to great acclaim, been adopted by a wide range of FMCG and grocery delivery companies.

Services Used

Industrial Design

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Analysis FEA

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Mechanical Engineering

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