MaxLoad Pro and TOPS Pro: Software for packaging optimisation, palletising and load planning
MaxLoad Pro and TOPS Pro are powerful software solutions for optimising packaging, pallet layouts and the loading of lorries and containers. Companies in industry, retail and logistics use the programmes to make better use of transport capacity, reduce costs and establish standardised processes in packaging and dispatch.
Whilst TOPS Pro focuses on packaging design, carton optimisation, palletising and load analysis, MaxLoad Pro concentrates on the optimal loading of transport vehicles. Together, both systems help companies to plan and optimise packaging, warehousing and transport processes in a data-driven manner.
The solutions are based on proven optimisation methods and have been in use worldwide for more than 35 years. Over 10,000 installations demonstrate the software’s widespread acceptance across a wide range of industries. By improving the space utilisation of packaging, pallets and cargo holds, companies can significantly reduce their logistics costs. According to the manufacturer, savings of up to 20 per cent on packaging, transport and storage costs are possible.
Areas of application and typical uses
MaxLoad Pro and TOPS Pro are used wherever products need to be efficiently packaged, palletised or transported.
Typical areas of application include:
- Shipping and transport logistics
- Warehouse and distribution centres
- Packaging development
- Production logistics
- E-commerce and fulfilment
- Consumer goods industry
- Food industry
- Automotive and spare parts logistics
TOPS Pro can be used to calculate optimal packaging sizes, packaging geometries and palletising patterns. The software assists in selecting suitable primary, secondary and transport packaging and helps to make the best possible use of the available space on pallets.
MaxLoad Pro enables the calculation of optimal loading plans for lorries and containers. Users can, for example, determine the required number of vehicles, select suitable container sizes or calculate the optimal load arrangement.
Key features and strengths
TOPS Pro supports companies throughout the entire packaging process:
- Optimisation of primary, secondary and transport packaging
- Calculation of efficient palletising patterns
- Loading optimisation for containers and lorries
- Analysis of stacking and pressure loads
- Creation of display pallets and display trays
- 3D visualisation of results
- Automatic generation of reports and analyses
A particular advantage is the integrated C.A.S.Y. Editor. This allows individual packaging shapes such as bottles, tubes, blister packs or displays to be modelled and subsequently optimised.
MaxLoad Pro supports the planning and optimisation of transport capacities:
- Calculation of optimal loading patterns
- Selection of suitable vehicle and container sizes
- Consideration of loading priorities and multi-stop scenarios
- Restriction-based planning taking into account stackability and weight limits
- Centre of gravity calculation and utilisation analysis
- Creation of detailed loading instructions
- Multilingual results reports
The software also takes real-world constraints into account, such as refrigeration units, loading zones or permitted stacking heights.
Structure and available modules
TOPS Pro offers various extensions and add-on modules for different requirements.
C.A.S.Y. Editor
Tool for creating custom packaging shapes and product geometries. The models created can be permanently saved in the database and reused for future projects.
MixPro
MixPro enables the planning of mixed pallets and display solutions. The software combines automatic optimisation with manual intervention options and supports users in creating complex pallet layouts.
TOPSePAC
TOPSePAC enables the use of TOPS Pro via a web browser or intranet. Users do not require a local installation and always work with the latest software version.
Manual optimisation
Both TOPS Pro and MaxLoad Pro allow automatically generated results to be adjusted manually. Users can incorporate their practical experience directly into the planning process and refine optimisation suggestions in a targeted manner.
Versions and licensing models
MaxLoad Pro is available as a single-user and network version. The software can be operated as a standalone application or integrated into existing IT environments.
TOPS Pro is available as a classic desktop solution and via TOPSePAC as a browser-based variant. This allows companies to flexibly adapt its use to their infrastructure.
Information on current licence models, maintenance contracts and extensions is available directly from SimPlan.
Integration and interfaces
Both solutions can be integrated into existing enterprise systems.
Supported systems include:
- ERP systems
- WMS systems
- Supply chain solutions
- Oracle applications
- EDI interfaces
- AS400 environments
- Custom data imports and exports
This enables product data, packaging information or dispatch orders to be automatically imported, and optimisation results to be transferred to downstream systems.
Frequently Asked Questions (FAQ)
Which companies are MaxLoad Pro and TOPS Pro suitable for?
The software is aimed at companies wishing to optimise their packaging, warehousing or transport processes. These include industrial companies, retail businesses, logistics service providers and fulfilment providers.
Can custom packaging be modelled?
Yes. With the integrated C.A.S.Y. Editor, even complex packaging shapes can be created and optimised.
Does the software support mixed pallets?
Yes. The MixPro module enables the planning and optimisation of mixed pallets and display solutions.
Can existing ERP or WMS systems be integrated?
Yes. Both solutions offer integration options for ERP, WMS and other enterprise systems.
Can optimisation results be visualised?
Yes. The results are presented via 3D visualisations, loading plans, palletising patterns, as well as comprehensive reports and statistics.
Manufacturer and supply
MaxLoad Pro and TOPS Pro are developed by TOPS Engineering. SimPlan is your point of contact for consultancy, software selection, licensing, implementation and support in German-speaking countries.
Our experts will assist you with the implementation of the software, integration into existing systems and with specific queries regarding packaging optimisation, palletising and load planning.
