Container Loading Optimisation in India: How 3D Weight-Balance Algorithms Cut Freight Damage Claims

Cargo damage is a costly, often hidden problem

As per Cogoport’s knowledge centre, hidden cargo damage accounts for 35% of the cargo insurance claims in India; it is costing approx. ₹2,800 crore every year. It is an estimated figure because the report does not give the source of this number. Until after delivery, the hidden damage goes unnoticed, when the goods are used for the first time or during unpacking. This can also happen when the outer packaging looks good.  At that time, this damage has happened during transportation.

Many claims start before the container moves

A 2025 article in Hellenic Shipping News, provided by maritime training firm MarinePALS, lists several causes of preventable cargo claims. It includes missed checks before loading and, not following the securing instructions, worn lashing equipment, and failure to notice early warning signs. The same article uses analysis from unnamed P&I clubs and discusses global shipping instead of just India. But the main issue is that a lot of cargo claims that the damage happened during loading, not just at sea.

Where manual load planning goes wrong

These are our analyses, not the findings of the above report. Many freight forwarders and 3PLs still plan container loads using their experience, spreadsheets, or paper. This can work until a container has different types of cargo. Then the planner has to consider fragile items, cartons that can be upright, stacking limits, and weight balancing.

The plan seems good, but damage still occurs when the heavier items are on the wrong side or when crushable goods are put under the heavier ones. There should always be another plan by the planner if the cargo does not fit in the first plan. This is also where mistakes take place.

What good load-planning software should do

This is also our analysis, not the source findings we have discussed above. Good load-planning software should create a plan automatically from the list of cargo, instead of having someone place items manually. It should have rules for items that are fragile, items that must stay upright, and stacking limits. These rules must be followed when the planning is going on instead of just being written in the notes.

Instead of just showing how the cargo is fitting, it should also show the weight balance. It should plan for the cargo that needs more than one container, and there should be loading instructions for the warehouse team. This can provide help in following the plan correctly.

Questions to ask before you adopt a tool

Ask these questions before choosing any load planning software:

1. Can cargo details be imported directly, so nobody has to enter the same information again?
2. Does the tool support the container types you use?
3. Can warehouse staff easily follow the loading instructions?
4. Can planners view the load in 3D before approving it?

These questions can help determine whether the software is really helpful in improving the load process or it will become a tool that no one is going to use.

How Eice SmartFit approaches container loading optimisation

Eice SmartFit is our browser-based container loading optimisation software. It does not need to be installed. Planners have a choice of standard 20ft, 40ft, or 40ft high-cube containers. They can also enter the custom container dimensions and payload limits. The details of the cargo can be entered through a grid or can be imported from a spreadsheet also. Smartfit creates a 3D load plan. It is based on the selected goals, using the available space that is possible, weight balance, and arrangement of cargo in the correct loading order.

You can view the plan in 3D, rotated, and zoomed in. Users can also check the loading steps one by one. The software checks weight distribution from front to back and from left to right. It gives the result a Good, Amber, or Red rating. It also has rules for fragile items, cargo that must stay upright or be placed at the bottom, and stacking limits.

If the cargo is not able to fit in one container, it moves the remaining cargo to additional containers and gives a summary of the shipment. You can export the loading plan as a PDF containing 3D snapshots, loading instructions, and a weight report. It is designed for freight forwarders, courier companies, and 3PL providers in India.

If your team plans container loads and container loading optimisation, we’d welcome the conversation.