GFS Design System — Box & Pallet Design Tools

01 Logistics Tools Overview Box sizing, pallet configuration, truck loading, and shipping optimization

Box Calculator

6

Standard GFS RSC sizes

Pallet Configs

5

Pre-built pallet patterns

Truck Types

4

Load planning templates

Warehouses

2

Edgewood, NY + Hermitage, PA

All tools use GFS standard dimensions. Pallet weights include 40 lb GMA pallet tare. Dimensional weight uses industry-standard divisor of 139 (domestic) or 166 (international). All calculators are interactive — results update on input change.

■ Global Food Solutions — Logistics Division — 131 Heartland Blvd, Edgewood, NY 11717

02 Box Size Calculator Product dimensions to recommended RSC with 3D mockup and inner pack layout

GFS Logistics — Box Sizing Tool

Standard RSC Calculator

GFS-LOG-BOX-001

Product Dimensions

Length (in)

Width (in)

Height (in)

Product Weight (lbs)

Qty Per Case

Standard GFS Box Sizes (RSC)

Code	L x W x H (in)	Cubic Ft	Max Weight	Flute	ECT
GFS-RSC-S1	12 x 12 x 12	1.00	30 lbs	C	32
GFS-RSC-S2	16 x 12 x 8	0.89	35 lbs	C	32
GFS-RSC-M1	20 x 16 x 12	2.22	50 lbs	B	44
GFS-RSC-M2	24 x 16 x 12	2.67	55 lbs	B	44
GFS-RSC-L1	24 x 20 x 16	4.44	65 lbs	BC	48
GFS-RSC-L2	28 x 20 x 16	5.19	70 lbs	BC	48

Recommended Box

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Recommended Size

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GFS Code

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Cubic Feet

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Dim Weight (lbs)

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Actual Weight (lbs)

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Volume Utilization

Inner Pack Arrangement

3D Box Preview

■ Box calculator uses GFS standard RSC inventory. Dimensional weight divisor: 139 (domestic FedEx/UPS).

03 Pallet Configuration Tool Case-to-pallet optimization with top-down and side-view SVG

GFS Logistics — Pallet Config

Ti x Hi Pallet Calculator

GFS-LOG-PAL-001

Case Length (in)

Case Width (in)

Case Height (in)

Case Weight (lbs)

Pallet Type

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Ti (Per Layer)

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Hi (Layers)

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Cases/Pallet

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Pallet Wt (lbs)

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Pallet Ht (in)

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Area Utilization

Top-Down Pallet View

Side View (Layers)

■ Weight limit: 2,500 lbs. Height limit: 48" stackable / 72" single-stack. Pallet tare: 40 lbs (GMA) / 0 lbs (slip sheet).

04 Truck Load Calculator Pallet-to-truck optimization with side-view SVG and multi-stop planning

GFS Logistics — Load Planning

Truck Load Optimizer

GFS-LOG-TRK-001

Pallet Width (in)

Pallet Depth (in)

Pallet Height (in)

Pallet Weight (lbs)

Truck Type

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Pallets/Truck

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Floor Utilization

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Weight Utilization

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Total Load (lbs)

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Double Stacked

Side-View Truck Loading Diagram

Multi-Stop Load Plan

Stop	Weight (lbs)	Load Position
1	14,400	TAIL (Last Off)
2	18,000	MIDDLE
3	14,400	NOSE (First Loaded)

■ Max legal gross weight: 80,000 lbs (truck + load). Standard 53' trailer: 26 pallets (48x40 double-pinwheeled). Interior dims: 630" L x 98.5" W x 110" H.

05 Standard GFS Packaging Reference Cases, pallets, wrap, corner boards, temp packaging, labels

Case Sizes (RSC / HSC / Display)

Code	Type	L x W x H	Flute	ECT	Burst	Use Case
GFS-RSC-S1	RSC	12 x 12 x 12	C	32	200#	40# cheese blocks, butter prints
GFS-RSC-S2	RSC	16 x 12 x 8	C	32	200#	Sliced cheese, frozen items
GFS-RSC-M1	RSC	20 x 16 x 12	B	44	275#	6-count #10 cans, bulk dry
GFS-RSC-M2	RSC	24 x 16 x 12	B	44	275#	Pancake cases, mixed packs
GFS-RSC-L1	RSC	24 x 20 x 16	BC	48	350#	Bulk institutional packs
GFS-RSC-L2	RSC	28 x 20 x 16	BC	48	350#	Large format, light products
GFS-HSC-01	HSC	20 x 12 x 6	E	32	200#	Retail display, half-slotted
GFS-DSP-01	Display	16 x 12 x 14	B	40	250#	POP display, printed 4-color

Pallet Types

Type	Size	Material	Tare Weight	Dynamic Load	Use
GMA Standard	48 x 40"	Hardwood	40 lbs	2,800 lbs	Primary shipping pallet
Block Pallet	48 x 48"	Hardwood	50 lbs	3,500 lbs	Barrel cheese, heavy product
Slip Sheet	48 x 40"	Fiberboard	2 lbs	2,200 lbs	Export, push-pull loads
Plastic	48 x 40"	HDPE	22 lbs	2,800 lbs	Clean room, dairy cold storage
Half Pallet	24 x 40"	Hardwood	20 lbs	1,400 lbs	Retail floor display

Stretch Wrap Specs

Spec	Value
Gauge	80 gauge (standard) / 60 gauge (machine)
Width	18" (hand) / 20" (machine)
Pre-stretch	200-250%
Wraps	Min 3 top, 3 bottom, 2 middle
Color	Clear (standard) / Black (security)

Corner Boards

Spec	Value
Material	Laminated paperboard
L-Angle	2" x 2" x 48" (standard)
Caliper	.160" (medium) / .225" (heavy)
Required	All 4 corners, all pallet shipments
Color	White (standard) / Kraft (economy)

Temperature-Controlled Packaging

Item	Temp Range	Duration	Size	Use Case
EPS Insulated Shipper (S)	33-40°F	24-48 hrs	12 x 10 x 8"	Small sample shipments
EPS Insulated Shipper (L)	33-40°F	24-48 hrs	20 x 16 x 14"	Multi-case refrigerated
Gel Pack (16 oz)	33-40°F	24 hrs	6 x 6 x 1"	Refrigerated supplement
Gel Pack (48 oz)	33-40°F	48 hrs	10 x 8 x 1.5"	Extended refrigerated
Dry Ice (5 lbs)	< 0°F	24-36 hrs	Pellet / block	Frozen shipments
Dry Ice (10 lbs)	< 0°F	36-72 hrs	Block	Extended frozen
Thermal Pallet Cover	Insulating	4-8 hrs	48 x 40 x 60"	Pallet-level temp protection

Standard Label Inventory

Label	Size	Material	Adhesive	Use
Shipping Label	4 x 6"	Direct thermal	Permanent	Case/carton shipping
Case Label	2 x 4"	Direct thermal	Permanent	Inner case identification
Pallet Placard	8.5 x 11"	Laser/inkjet	Sleeve/clip	Pallet-level identification
KEEP REFRIGERATED	3 x 5"	Synthetic	Freezer-grade	Cold chain indicator
KEEP FROZEN	3 x 5"	Synthetic	Freezer-grade	Frozen chain indicator
FRAGILE	3 x 5"	Paper	Permanent	Handling instruction
THIS SIDE UP	3 x 5"	Paper	Permanent	Orientation arrow

■ All GFS packaging meets ISTA 3A transit-test standards. ECT = Edge Crush Test (lbs/in).

06 Shipping Label Templates GFS-branded case labels, pallet placards, BOL, and temperature indicators

Standard Case Label (4 x 6")

GLOBAL FOOD SOLUTIONS 4 x 6 CASE

ProductBongards Cheddar Barrel 640#

Item #GFS-CHD-640-BB

Lot2026-0519-A01

Mfg Date05/19/2026

Best By11/19/2026

Net Wt640 LBS

0 12345 67890 5

Pallet Placard (8.5 x 11")

GFS PALLET PLACARD 8.5 x 11

PO# 4501892

Ship ToGood Eats Dist. - Newark, NJ

ItemBongards Cheddar 40# Block

Item #GFS-CHD-040-BK

Qty56 cases / 2,240 lbs

Lot2026-0519-B03

Pallet1 of 4

Ship Date05/19/2026

PO-4501892-PAL-001

Bill of Lading Label

GFS BILL OF LADING BOL

BOL #GFS-BOL-20260519-001

ShipperGlobal Food Solutions, Inc.

Origin131 Heartland Blvd, Edgewood, NY

ConsigneeGood Eats Distribution

Dest400 Industrial Pkwy, Newark, NJ

Pallets4

Total Wt8,960 lbs

CarrierGFS Fleet - Truck #108

Temp36-40°F Refrigerated

GFS-BOL-20260519-001

Temperature Indicator — Refrigerated

TEMPERATURE INDICATOR 3 x 5

KEEP REFRIGERATED

33°F – 40°F

DO NOT FREEZE • DO NOT LEAVE UNREFRIGERATED

Temperature Indicator — Frozen

TEMPERATURE INDICATOR 3 x 5

KEEP FROZEN

0°F or Below

DO NOT THAW • REFREEZE IMMEDIATELY IF THAWED

Handling Label — This Side Up

HANDLING INSTRUCTION 3 x 5

THIS SIDE UP

■ All labels print on Zebra ZT411 (4" thermal) or standard laser (pallet placards). Label data is illustrative.

07 Weight & Volume Conversion Calculator lbs/kg, cu in/cu ft/cu m, dimensional weight, case weight estimator

Weight Converter

Pounds (lbs)

Kilograms (kg)

Ounces (oz)

Grams (g)

Volume Converter

Cubic Inches (in³)

Cubic Feet (ft³)

Cubic Meters (m³)

Dimensional Weight

L (in)

W (in)

H (in)

Dim Factor

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Dim Weight (lbs)

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Cubic Feet

Case Weight Estimator

Product Weight (lbs)

Count Per Case

Tare Weight (lbs)

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Net Weight (lbs)

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Gross Weight (lbs)

■ Dimensional weight = (L x W x H) / dim factor. Billable weight = max(actual, dimensional).

08 Pallet Pattern Library Pre-built patterns for common GFS products with top-down and side views

640# Barrel Cheddar (Bongards)

Ti x Hi1 x 1

Per Pallet1 barrel

Pallet Weight680 lbs

Pallet Type48 x 48 Block

Height42"

Top Down

Side View

40# Block Cheddar (Bongards)

Ti x Hi7 x 8

Per Pallet56 blocks

Pallet Weight2,280 lbs

Pallet Type48 x 40 GMA

Height46"

Top Down

Side View

#10 Cans (6/case)

Ti x Hi10 x 10

Per Pallet100 cases

Pallet Weight2,440 lbs

Pallet Type48 x 40 GMA

Height50"

Top Down

Side View

Butter Prints (36/pallet)

Ti x Hi6 x 6

Per Pallet36 cases

Pallet Weight1,840 lbs

Pallet Type48 x 40 GMA

Height44"

Top Down

Side View

Frozen Pancakes (80/pallet)

Ti x Hi8 x 10

Per Pallet80 cases

Pallet Weight2,040 lbs

Pallet Type48 x 40 GMA

Height50"

Top Down

Side View

■ Patterns are GFS standard configurations. Alternate patterns may be used for mixed-product pallets.

09 Warehouse Slot/Bin Size Reference Edgewood and Hermitage rack configurations, bin sizes, floor stacking rules

Edgewood, NY — 131 Heartland Blvd

Primary Warehouse

Zone	Type	Slot Size	Temp
A1-A20	Pallet Rack	48" W x 48" D x 72" H	Ambient
B1-B16	Pallet Rack	48" W x 48" D x 60" H	Cooler 36°F
C1-C12	Case Pick	24" W x 48" D x 36" H	Cooler 36°F
D1-D8	Bulk Floor	48" x 48" floor mark	Cooler 36°F
F1-F6	Freezer Rack	48" W x 48" D x 60" H	Freezer 0°F
S1-S4	Staging	Open dock	Ambient

Hermitage, PA — 2500 Freeland Road

Secondary Warehouse

Zone	Type	Slot Size	Temp
H1-H30	Pallet Rack	48" W x 48" D x 72" H	Ambient
H31-H50	Pallet Rack	48" W x 48" D x 60" H	Cooler 36°F
HC1-HC8	Case Pick	24" W x 48" D x 36" H	Cooler 36°F
HB1-HB12	Bulk Floor	48" x 48" floor mark	Mixed
HF1-HF10	Freezer Rack	48" W x 48" D x 60" H	Freezer -10°F
HS1-HS6	Staging	Open dock	Ambient

Floor Stacking Rules

Product Type	Max Stack Height	Max Layers	Corner Boards	Notes
40# Cheese Blocks	48"	2 pallets	Required	No stack if top pallet > 2,000 lbs
640# Barrels	42" (single)	1 pallet	N/A	Never stack barrels
#10 Cans	96"	2 pallets	Required	Max 2,500 lbs per pallet for stacking
Frozen Pancakes	96"	2 pallets	Required	Freezer zone only
Butter	48"	1 pallet	Required	No stacking — crush risk

Warehouse Cross-Section — Rack Configuration (Edgewood)

■ Edgewood: 42,000 sq ft total. Hermitage: 68,000 sq ft total. All racks are selective pallet racking.

10 Freight Class Reference NMFC classes, density calculator, cost impact for common GFS products

Common GFS Product Freight Classes

Product	NMFC #	Freight Class	Density (lbs/ft3)	Notes
Cheddar Cheese (blocks)	22700	85	22-30	Refrigerated, density-based
Cheddar Cheese (barrels)	22700	70	30+	High density, single-unit
Butter (prints/blocks)	22050	85	22-30	Refrigerated
Frozen Pancakes	55600	92.5	15-22	Frozen, less dense
#10 Cans (food)	55440	70	30+	Very dense, ambient
Dry Goods (boxed)	100250	100	12-15	Light, medium density
Insulated Shippers	46440	150	6-8	Low density, high class

Freight Class vs. Density (lbs/ft3)

Class	Density Range	Cost Multiplier	Example
50	50+ lbs/ft3	1.0x (base)	Steel, bricks
55	35-50 lbs/ft3	1.1x	Dense canned goods
60	30-35 lbs/ft3	1.2x	Car parts, hardware
65	22.5-30 lbs/ft3	1.3x	Beverages, liquids
70	15-22.5 lbs/ft3	1.5x	Barrel cheese, #10 cans
77.5	13.5-15 lbs/ft3	1.7x	Tires, machinery
85	12-13.5 lbs/ft3	1.9x	Cheese blocks, butter
92.5	10.5-12 lbs/ft3	2.1x	Frozen pancakes
100	9-10.5 lbs/ft3	2.4x	Dry goods, bottles
110	8-9 lbs/ft3	2.7x	Cabinets, frames
125	7-8 lbs/ft3	3.0x	Appliances
150	6-7 lbs/ft3	3.5x	Insulated shippers
175	5-6 lbs/ft3	4.0x	Clothing, textiles
200	4-5 lbs/ft3	4.5x	Auto sheet metal
250	3-4 lbs/ft3	5.2x	Mattresses, bamboo
300	2-3 lbs/ft3	6.0x	Wood cabinets
400	1-2 lbs/ft3	7.5x	Deer antlers
500	< 1 lb/ft3	9.0x	Ping pong balls, bags

Density Calculator

Total Weight (lbs)

L (in)

W (in)

H (in)

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Density (lbs/ft3)

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Est. Freight Class

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Cubic Feet

              Freight class determines LTL shipping cost. Lower class = denser product = lower cost per pound. Always verify NMFC classification with your carrier for exact class assignment.
            

■ NMFC = National Motor Freight Classification. Cost multipliers are approximate industry averages.

11 Shipping Cost Estimator Quick cost estimate by mode: LTL, FTL, parcel, reefer surcharge

GFS Logistics — Cost Estimator

Freight Cost Calculator

GFS-LOG-CST-001

Shipping Mode

Weight (lbs)

Distance (miles)

Freight Class

Temperature

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Base Rate

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Fuel Surcharge

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Temp Surcharge

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Estimated Total

          Estimates use industry-average LTL rates. Actual rates vary by carrier, lane, and contract. Fuel surcharge estimated at 15%. Reefer surcharge: +20%. Frozen surcharge: +30%.
        

■ For accurate quotes, contact GFS Logistics at (877) 728-5550 or logistics@GlobalFoodSolutions.co.