Ramadan triggers significant increases in production, storage, and shipping within a very short timeframe. Operations and logistics teams typically prepare product stocks well in advance, but distribution support materials such as layer pads are often overlooked in the planning process.
When layer pads are unavailable, distribution operations are forced to proceed without adequate stacking protection, putting products at risk of damage.
On the other hand, excess layer pad stock left unused after peak season drives up storage costs and ties up working capital that could otherwise be allocated to other needs.
For this reason, ALVAboard has put together this article to help you calculate layer pad requirements for the Ramadan distribution surge, so your operations run smoothly without shortages or waste.
Why Is Layer Pad Planning Important Before Ramadan?
There are several reasons why layer pad planning for the Ramadan period deserves more careful attention than planning for ordinary months.
- Pallet volume increases significantly. More pallets in motion means more layer pads are needed per unit of time.
- Stacking heights become more extreme than normal. Limited warehouse space that must accommodate larger stocks forces higher stacking, which means more layers are required per pallet.
- Handling frequency increases. Higher activity levels — including goods receiving, inter-zone transfers, loading, and unloading — during peak season raise the likelihood of layer pad damage, requiring faster replacement than usual.
- Procurement lead times can be longer. Because demand for packaging materials rises across industries during this period, orders must be placed earlier to ensure timely availability.
- Financial and operational consequences of inaccurate estimates. A miscalculation can disrupt distribution due to insufficient stack protection, or conversely, create capital waste from excess stock that piles up unused.
Key Components in Calculating Layer Pad Requirements
1. Number of Pallets Used During Ramadan
This includes pallets leaving the production warehouse, pallets moving within the distribution warehouse, and pallets shipped to final distribution points.
The pallet count can be calculated by dividing the projected volume of products to be distributed by the product capacity per pallet for each relevant SKU. Use historical data from the previous Ramadan as a reference, adjusted for this year’s projected volume growth.
2. Number of Product Layers per Pallet
The number of layers per pallet varies depending on product size and weight, maximum pallet capacity, and the stacking height permitted by the product’s packaging specifications.
The number of layer pads required per pallet equals the number of product layers minus one, since layer pads are placed between product layers — not beneath the first layer or on top of the last. For example, a pallet with 5 product layers requires 4 layer pads.
3. Pallet Rotation Frequency
Rotation frequency determines how many times a layer pad is used throughout the Ramadan period. If layer pads are reusable and remain in good condition after one delivery cycle, the same pads can be used again in subsequent cycles.
For reusable PP corrugated layer pads, the service life per unit can reach several distribution cycles, depending on handling conditions.
4. Operational Buffer (Safety Stock)
Safety stock for layer pads acts as a buffer against unexpected variability — whether from demand exceeding projections or from layer pads wearing out faster than estimated.
The recommended safety stock level ranges from 10 to 20 percent of the core requirement, depending on the degree of forecast uncertainty and the operational consequences of a stockout. For the Ramadan period specifically, a safety stock of 15 to 20 percent is advised.
Base Data to Collect Before Calculating
Gather the following data before starting your calculation:
- Last year’s Ramadan distribution volume
- Projected demand growth for this year
- Number of product units per pallet and number of product layers per pallet
- Average stacking height in the warehouse and during transport
- Number of delivery cycles during the Ramadan period, including the duration counted as peak season
Basic Formula for Calculating Layer Pad Requirements
The calculation follows a straightforward sequence from input data to a total estimate ready for procurement planning.
Step 1: Calculate total pallets during the Ramadan period
Total Pallets = Product Volume (units) ÷ Product Capacity per Pallet
Step 2: Calculate layer pad usage per cycle
Layer Pads per Cycle = Total Pallets × (Number of Layers per Pallet − 1)
Step 3: Adjust for rotation frequency (reusable layer pads)
If layer pads are reusable and rotated, the number of layer pad units required is:
Layer Pad Units Needed = Layer Pads per Cycle ÷ Number of Rotations per Unit
Step 4: Add safety stock
Total Requirement = Layer Pad Units Needed × (1 + Safety Stock Percentage)
Sample Calculation Simulation for Ramadan Layer Pad Requirements
The following is a simulation for an FMCG distribution company planning a 6-week Ramadan distribution period under these conditions:
Assumed data:
- Distribution volume: 50,000 product cartons
- Capacity per pallet: 50 cartons
- Product layers per pallet under normal conditions: 4 layers
- Product layers per pallet during peak season: 6 layers
- Reusable layer pads, estimated 3 rotations per unit during the Ramadan period
- Safety stock: 15%
| Component | Normal Conditions | Peak Season |
| Total pallets | 50,000 ÷ 50 = 1,000 pallets | 50,000 ÷ 50 = 1,000 pallets |
| Layer pads per cycle | 1,000 × (4−1) = 3,000 sheets | 1,000 × (6−1) = 5,000 sheets |
| Units needed (3 rotations) | 3,000 ÷ 3 = 1,000 units | 5,000 ÷ 3 = 1,667 units |
| With 15% safety stock | 1,000 × 1.15 = 1,150 units | 1,667 × 1.15 = 1,917 units |
This simulation shows that increasing stacking height from 4 to 6 layers during peak season raises layer pad requirements by 67 percent compared to normal conditions.
It should be noted, however, that the figures above are illustrative and based on simplified assumptions. Actual calculations must use company-specific operational data to produce accurate estimates.
Conclusion
The distribution surge during Ramadan calls for distribution support material planning that is just as rigorous as planning for the core product stock itself.
Accurate layer pad calculations help maintain pallet stability throughout the intensive distribution period while avoiding waste from excess unused stock.
The three variables that matter most in this calculation are pallet volume, the number of layers per pallet during peak season, and the rotation frequency of reusable layer pads.
For reusable layer pads that support intensive distribution operations, ALVAboard is available as a local manufacturer reference in your layer pad evaluation and procurement process for Ramadan peak season.
Get in touch with the ALVAboard team today to discuss your layer pad needs!
