TOPS Pro Tutorial - TOPS - Packaging Software

TOPS ® Pro Tutorial 

Package Design and Palletization 

Introduction..................................................................................................1 

Getting Started .............................................................................................2 

General Overview ........................................................................................3 

Control Panel .........................................................................................4 

Menu Bar ...............................................................................................5 

Windows Toolbar...................................................................................6 

Template Toolbar...................................................................................8 

Button-Style Menus ...............................................................................8 

Package Design Sequence Area.............................................................9 

Shortcut Buttons ..................................................................................10 

Exercise #1: Perform a Simple Analysis ..................................................11 

Exercise #2: Perform a Complex Analysis ...............................................23 

Exercise #3: Perform a Knockdown Analysis ..........................................48 

Exercise #4: Design the Output From an Analysis...................................58 

Exercise #5: Publish an Analysis to the Web or Network........................63 

Exercise #6: New CASY Features............................................................66 

Exercise #7: Design a Mixed Pallet...........................................................71 

Exercise #8: Design a Mixed Tray ............................................................77 

TOPSePAC ................................................................................................85

TOPS ® Pro Tutorial 

Introduction 

Thanks for your interest in the TOPS Pro Demonstration (Demo) software. 

TOPS Pro is designed to meet the most advanced needs of the packaging 

professional. However, this tutorial is designed to give a general 

overview of the primary functions of the software. The tutorial does not 

explore the full range of the TOPS Pro software capabilities, but is 

designed only as a basic tutorial that walks you through the core of the 

system. 

Getting Started: Walks you through the process of installing the 

TOPS Pro demo software and logging into the system. 

Exercise #1: Perform a Simple Analysis: Walks you through on 

how to find the optimal solution for loading shipcases onto a pallet. 

Exercise #2: Perform a Complex Analysis: Walks you through an 

analysis to find the optimal solution for loading bottles into a carton, 

into a shipcase, onto a pallet and onto a truck. You’ll also use the 

CASY (Create A Shape Yourself) system to design a custom-shaped 

can and tray. 

Exercise #3: Perform a Knockdown Analysis: Walks you through 

a knockdown analysis to find the optimal solution for loading 

knockdown (collapsed) boxes onto a pallet. 

Exercise #4: Design the Output from an Analysis: Walks you 

through the process of designing what information will go into your 

printed output and what that output will look like. 

Exercise #5: Publish an Analysis to the Web or Network: Walks 

you through the process of publishing an analysis to the Web or to a 

local network, where other people can view the analysis. 

Exercise #6: New CASY Features: Gives an overview of the new 

primary shapes and shape functions in CASY. 

Exercise #7: Design a Mixe Pallet: Walks you through on how to 

create a mixed pallet. 

Exercise #8: Design a Mixed Tray: Walks you through on how to 

create a mixed pallet. 

TOPS Pro Tutorial 1

If you experience problems or difficulties while using the TOPS Pro 

software, please call the TOPS Technical Support Department or your 

TOPS sales representative at (972) 739-8677. 

Getting Started 

This section of the tutorial walks you through the installation process and 

gets you logged into the system. To install the TOPS Pro demo software, 

follow these instructions: 

1. Start Windows. 

2. Insert the TOPS Pro CD into your CD-ROM drive. 

Note: For more information on installing the software, please refer to 

the installation sheet included with the software package. 

Follow the instructions on the screen until the installation is complete. 

3. Double-click on the TOPS for Windows DEMO icon. 

System Response: The User Login panel appears, as pictured below. 

4. Select the user group you belong to and click on the Login button. 

System Response: The Control Panel appears, as pictured on page 4. 

Congratulations! At this point, the installation is complete and you've 

logged on. Now you're ready to go to work with TOPS Pro. First, we'll 

walk through a General Overview, where you'll get acquainted with the 

Control Panel and the layout of the system. 

After you're familiar with the primary elements, then we'll walk through 

some real-world packaging analyses. These exercises will demonstrate 

the ease and flexibility with which TOPS Pro generates a number of 

detailed solutions for the packing professional. 

2 TOPS User Guide Supplement and Tutorial

General Overview 

Before you start using TOPS Pro, let's get acquainted with the primary 

features and functions of TOPS Pro, as listed below: 

Control Panel: The primary window in the system that allows you to 

select the type of analysis you want to perform, the stages to be used in 

the analysis, and the dimensions of each stage. 

Menu Bar: Provides a number of pull-down menus that allow you to 

perform common tasks such as setting print parameters, changing 

languages and defining stages in an analysis. 

Windows Toolbar: Contains a number of icons that allow you to 

perform standard, commonly used functions. 

Template Toolbar: Contains a number of buttons that give you easy 

access to analysis templates set up in the system. 

Button-Style Menus: Allow you to set up a Package Design 

Sequence, in which you select the various stages to be used in an 

analysis. 

Package Design Sequence Area: The area on the screen in which 

you define a series of stages that comprise an analysis. For example, 

you might set up a sequence in which you analyze how to best load 

shipcases onto a pallet. 

Shortcut Buttons: Allow you to view solution panels for an analysis 

record or calculate solutions for an analysis. 

Let's discuss these features in more detail. 


Control Panel 

When you login to the system, the Control Panel appears, as pictured 

below. The Control Panel contains all the primary features of the system: 

Menu Bar, Windows Toolbar, Template Toolbar, Package Design 

Sequence Area, Button-Style Menus and Shortcut Buttons. 

Menu Bar 

Package Design Sequence Area 

Windows 

Toolbar 

Template 

Toolbar 

Button-Style Menus 

Shortcut Buttons 

The Control Panel is the primary panel in the system. It is the working 

area from which you will select the type of analysis you want to perform, 

select the stages to be used in the analysis and define the dimensions of 

each stage. 


Menu Bar 

The Menu Bar, pictured below, provides a number of drop-down menus. 

These menus provide options that allow you to perform common tasks, 

many of which are duplicated on the Button Bar and Shortcut Buttons. 

The list below gives a brief description of the eight menus on the Menu 

Bar: 

File Menu: Allows you to create new records, open existing records, 

save records and set up print parameters. 

Edit Menu: Allows you to copy text and images to the Windows 

clipboard, as well as work with secondary pallet patterns. 

View Menu: Allows you to view graphic images in a number of 

formats: 3-D, front, side, split screen, quad screen and others. 

Define Menu: Allows you to define parameters for new products, 

cartons, shipcases, pallets, vehicles, etc. 

Tools Menu: Allows you to revise your TOPS Pro configuration, the 

language used in TOPS Pro (TOPS Pro is used worldwide), stacking 

strength parameters, color selections, etc. 

Export Menu: Allows you to export different types of graphic files 

(.bmp, .tiff, .jpeg), analyses, product reports, etc. 

Supervisor Menu: Allows you to perform supervisor functions such 

as login/logout tasks, access approval and denial, template setup, etc. 

Help Menu: Allows you to display Help information for all features 

and functions in the system. 


Windows Toolbar 

The Windows Toolbar, pictured below, contains a number of icons that 

allow you to perform standard, routine functions. 

The table below and on the next page outlines each icon in the Toolbar 

and its corresponding purpose. 

Windows Toolbar 

This Icon... 

Allows You To Do This 

New Analysis: Clears the Package Design Sequence 

area and allows you to start a new analysis. 

New Based on Predefined Template: Opens the Open 

Analysis dialog box and allows you to select a 

predefined analysis template. 

Open: Opens the Open Analysis dialog box and allows 

you to select an analysis. 

Save: Saves the analysis. 

Print: Prints the analysis. 

Previous: Takes you to the previous step in the Package 

Design Sequence for an analysis. 

Next: Takes you to the next step in the Package Design 

Sequence for an analysis. If there is no next step, this 

icon takes you back to the Package Design Sequence. 

Cancel to Package Design Sequence: Cancels out of 

the active analysis and takes you back to the Package 

Design Sequence area, where you can start over. 

Design CASY Primary Package: Opens the CASY 

Primary Package Screen. 


Windows Toolbar (cont.) 

This Icon... 

Allows You To Do This 

Design CASY Shipping Case/Tray: Opens the CASY 

Shipping Case/Tray Screen. 

MixPro Mixed Pallet Editor: Opens the MixPro Mixed 

Pallet Editor, used to create mixed pallets. 

MixPro Mixed Tray Editor: Opens the MixPro Mixed 

Tray Editor, used to create mixed trays. 

Modify Primary Pack Parameters: Opens the 

parameters dialog box for the appropriate primary 

package (bottle, can, etc.) in the Analysis View. 

Modify Intermediate Pack Parameters: Opens the 

parameters dialog box for the appropriate intermediate 

packer (, etc.) in the Analysis View. 

Modify Shipcase Parameters: Opens the Shipcase 

Parameters dialog box in the Analysis View. 

Modify Unitload Parameters: Opens the Unitload 


Modify Vehicle Parameters: Opens the Vehicle 


Switch to Related KD Analysis: Not currently active. 

Switch to Related Box Analysis: Not currently active. 

Show CASY: Serves as a toggle switch to turn on or off 

the CASY graphics display. 

Stacking Strength: Opens the Stacking Strength dialog 

box. 

All Stages Enhanced View: Opens an All View pane 

with all stages of an analysis in the Analysis View. 

Flying Toolbar: Serves as a toggle switch to turn on or 

off the Flying Toolbar. 


The Windows Toolbar provides a direct link to the parameters dialog 

boxes. In previous releases of TOPS, if you were in the middle of an 

analysis and needed to modify parameters for a shipcase, for example, you 

had to cancel out of the analysis, go back to the Package Design Sequence 

Area and access the dialog box from there. 

Now, the Toolbar has icons that take you directly to the parameters dialog 

box for primary packages, intermediate packers, shipcases, unitloads and 

vehicles. You can modify those parameters without losing your place in 

the analysis process. 

Template Toolbar 

The Template Toolbar, pictured below, gives you easy access to analysis 

templates set up in the system. 

Notice the first button in the toolbar to the 

left. This template button shows four stages 

of an analysis: Can/Cylinder-Shipcase- 

Pallet-Vehicle. 

If you click on this button, TOPS Pro 

automatically inserts the corresponding 

icons in the Package Design Sequence Area. 

As you set up the stages that make up an 

analysis, TOPS Pro allows you to save the 

analysis as a template and add it to the 

Template Toolbar. For more information, 

please refer to “Exercise 1: Perform a 

Simple Analysis.” 

Button-Style Menus 

The Button-Style Menus, pictured below, allow you to set up a Package 

Design Sequence with the various stages to be used in an analysis. 


As you can see, there are six Button-Style Menus, each of which 

represents a stage of an analysis and has a corresponding icon. In the 

figure above, the six active stages are bulk, film bag, carton, shipper, 

pallet and truck. 

Each menu contains a list of items that allow you to define the stages of an 

analysis with any combination of items you need. To select an item, click 

on that item in the list, then click on the button at the top of the list. As 

you select each stage, the corresponding icon will appear in the Package 

Design Sequence Area of the Control Panel. To remove an icon from that 

area, simply click on the button again. 

Note: Be aware that there are a few duplications in the button-style 

menus that should be clarified. 

Carton Icons: There are two Carton icons. The Box Carton icon 

(green) displays the Carton Parameters dialog box. The Intermediate 

Pack Carton icon (blue) displays the Intermediate Pack Parameters 

dialog box. 

Tray Icons: There are two Tray icons. The Intermediate Pack Tray 

icon (blue) displays the Intermediate Pack Parameters dialog box. The 

Shipper Tray icon (yellow) displays the Shipcase Parameters dialog 

box. 

Bag Icons: There are two Bag icons. The Film Bag icon (green) and 

the Shipper Bag icon (yellow) both display the Bag Parameters dialog 

box. However, you'll use the first Film Bag icon to design a bag that 

contains a product. You'll use the Shipper Bag icon to put a bag onto a 

pallet. 

Bottle Icons: There are two Bottle icons. The Bottle icon (green) and 

the Shipper Bottle icon (yellow) both display the Bottle Parameters 

dialog box. However, you'll use the first Bottle icon to design a bottle 

that goes into a shipcase. You'll use the Shipper Bottle icon to design 

a bottle that goes onto a pallet. 

Package Design Sequence Area 

The Package Design Sequence Area is the area on your screen in which 

you define a series of stages selected to perform an analysis. For example, 

let's say you selected six stages from the Button-Style Menus: bulk, bag, 

carton, shipper, pallet and truck. The corresponding icons will appear in 

the Package Design Sequence Area, as pictured here. 


The icons you see in this figure are often referred to, respectively, as the 

Bulk Parameters icon, the Bag Parameters icon, the Carton Parameters 

icon, the Shipper Parameters icon, the Unitload Parameters icon and the 

Transit Vehicle Parameters icon. 

This represents a Package Design Sequence in which you'll find the best 

solution for this analysis: bulk product into a bag, into a carton, into a 

shipcase, onto a pallet and into a truck. 

Next, when you click on any of these icons, a dialog box will appear and 

allow you to define the parameters of that particular stage in the sequence. 

For example, when you click on the Bottle icon, the Bottle Parameters 

dialog box appears, and you'll tell the system precisely how your bottles 

are designed in terms of dimensions, weight, shape, etc. 

Shortcut Buttons 

The Shortcut Buttons, as pictured below, allow you to view and calculate 

solutions for an analysis. 

Let's briefly define these shortcut buttons: 

View Button: Allows you to display and view the solution panels 

(Analysis View) for a selected analysis. This function becomes active 

only after an analysis has been completed. 

Calc Button: Allows you to calculate solutions for an analysis. After 

you've selected all the stages for the analysis and defined parameters 

for each stage, the Calc button tells the system to generate all possible 

solutions for the analysis, given the data you entered. 

If you click on the Calc button and your analysis is incomplete – you 

forgot to enter a necessary detail – TOPS Pro automatically displays 

the appropriate dialog box and prompts you to enter the missing data. 

If you've simply made changes to the analysis, the system allows you 

to look over the changes you made before you continue. 


Exercise #1: Perform a Simple 

Analysis 

In this exercise, you'll perform a very simple analysis: carton into a 

shipcase onto a pallet. This analysis is considered simple because it 

involves only three stages – carton, shipcase and pallet. 

Objective: Find the optimal solution for loading cartons into shipcases 

and onto a pallet. 

In this analysis, the various stages have these general characteristics: 

Each carton measures 6 inches long, 2 inches wide and 4 inches high. 

Each shipcase measures 12 inches long, 10 inches wide and 8 inches 

high. 

Each shipcase weighs 25 pounds. 

You’ll use three pallet types to calculate a solution – GMA (Notched), 

Europallet and GMA (Metric-Block). The pallet measures 48 inches 

by 40 inches. 

The load of shipcases will not exceed 60 inches high. 

The load of shipcases will not exceed 9,999 pounds. 

The load of shipcases will not exceed four layers. 

To perform this analysis, you'll start from the Control Panel and work 

through four simple sets of procedures, in this order: 

1. Define the Package Design Sequence. 

2. Save the Package Design Sequence as a template. 

3. Define the carton parameters. 

4. Define the shipcase parameters. 

5. Select pallet types and define the unitload (pallet) parameters. 

6. Generate possible solutions, make a decision and save the analysis to a 

folder. 

7. Email the Stacking Strength Board Combo List. 

8. Send the analysis to Microsoft Word. 


Step 1: Define the Package Design Sequence 

To define the Package Design Sequence, start from the Control Panel and 


1. Click on the Carton button. 

2. Click on the Shipper button. 

3. Click on the Pallet button. 

System Response: The Carton, Shipper and Pallet icons appear in the 

Package Design Sequence area of the panel, as pictured below. 

Step 2: Save the Package Design Sequence as a 

Template 

The shipcase-to-pallet sequence is a routine analysis that you’ll perform 

frequently. TOPS Pro allows you to save this analysis as a template and 

add it to the Template Toolbar. 

To save the Package Design Sequence as a template, follow these 

instructions: 

1. Go to the Menu Bar and open the File Menu. 

2. From the File Menu, click on the Save As Template option. 

System Response: The Analysis Save As dialog box appears, as 

pictured below. 

3. In the Description field, enter the name of the new template (e.g., 

Carton-Shipcase-Pallet). 


4. Click on the OK button. 

System Response: TOPS Pro saves the new template to the database 

and adds it to the Template Toolbar. The next time you want to 

perform this analysis, you’ll simply go to the Template Toolbar and 

click on the template button for the analysis. 

Note: To display the Template Toolbar on the Control Panel, go to 

the Configuration dialog box and select the Display Template Buttons 

option. 

Step 3: Define Carton Parameters 

To define your carton parameters, follow these instructions: 

1. Click on the Carton icon in the Package Design Sequence Area. 

System Response: The Carton Parameters dialog box appears, as 


2. Use the following fields to define the carton parameters. Use the Tab 

key to move from field to field. 

Carton: Select Fixed. 

Length: Enter 6. 

Width: Enter 2. 

Height: Enter 4. 

Vertical: Check the box to the right of the Height field. 

As you enter parameters, a Graphic Online Display (g.o.d.) feature 

appears in the bottom, right of the panel. This feature shows how the 

carton will look as you change dimensions. This feature allows you to 

visually inspect your work and correct flaws as you go along. 

3. After completing the shipcase parameters, click on OK. 

System Response: TOPS Pro stores your carton parameters to 

memory and redisplays the Control Panel. 


Step 4: Define Shipcase Parameters 

To define your shipcase parameters, follow these instructions: 

1. Click on the Shipper icon in the Package Design Sequence Area. 

System Response: The Shipcase Parameters dialog box appears, as 


This dialog box allows you to define parameters of the shipcase in a very 

precise, thorough manner. In addition to the general dimensions outlined 

in the objective of this analysis, you'll also define these parameters: 

The flute type is a C flute. 

Shipcase dimensions are measured from the outside. 

The 8-inch height is the dimension vertical to the pallet. 

2. Use the following fields to define the shipcase parameters. Use the 

Tab key to move from field to field. 

Flute: Use the default (C Flute). 

Dimensions: Use the default (Outside). 




Case: Enter 25. 

Vertical: Check the box to the right of the Height/Slack field. 

As you enter parameters, a Graphic Online Display (g.o.d.) feature 

appears in the bottom, right portion of the panel and shows how the 

shipcase will look as you change dimensions. This feature allows you to 

visually inspect your work and correct flaws as you go along. 

3. After completing shipcase parameters, click on OK. 

System Response: TOPS Pro stores your shipcase parameters to 



Step 5: Select Pallet Types and Define Unitload 

(Pallet) Parameters 

To select the pallet types to be used, follow these instructions: 

1. Click on the Pallet icon in the Package Design Sequence Area. 

System Response: The UnitLoad Parameters dialog box appears, as 


2. Select the Multi Pallets option, then click on the Select Pallets button. 

System Response: The Select Items dialog box appears, as pictured 

below. 

Notice that the dialog box is divided into two windows: 

The window on the left (Available Pallets) includes a list of pallet 

styles available to be used in the calculation. 

The window on the right (Selected Pallets) includes a list of pallet 

styles that have been selected to be used in the calculation. (The GMA 

(Notched) pallet is selected by default.) 


In this exercise, you’ll select three pallet styles to be included in the 

calculation – GMA (Notched), Europallet and GMA (Metric-Block). The 

GMA (Notched) pallet is already selected by default. 

3. Click on the Europallet style. 

4. Click on the Add button. 

System Response: TOPS Pro adds the Europallet style to the 

Selected Pallets window. 

5. Click on the GMA (Metric-Block) style. 


System Response: TOPS Pro adds the GMA (Metric-Block) style to 

the Selected Pallets window. 

At this point, the Selected Pallets window includes three pallet styles – 

GMA (Notched), Europallet and GMA (Metric-Block). 

7. When your pallet selections are complete, click on OK. 

System Response: TOPS Pro stores the selected pallet styles to 

memory and redisplays the UnitLoad Parameters dialog box. 

This dialog box allows you to define the parameters of the load to be 

placed on your pallet – i.e., the particulars of how the shipcases will be 

loaded onto the pallet. For the purposes of this demo, we'll only use a 

handful of these options. 

Remember in the objective of this analysis, the pallet is a standard GMA 

(notched) pallet, which measures 48 inches by 40 inches, and the load of 

shipcases will not exceed a height of 60 inches high, a weight of 9,999 

pounds or more than four layers of shipcases. In addition to these 

measures, we'll also define these parameters: 

The maximum overhang of the load is 1 inch long and 1 inch wide. 

The maximum underhang of the load is 15 inches long and 15 inches 

wide 

8. Use the following fields to define the shipcase parameters: 

Maximum Height: Click on the field and enter 60. 

Maximum Weight: Use the default (9999). 

Maximum Layers: Click on the field and enter 4. 

Maximum Overhang/Length: Use the default (1). 

Maximum Overhang/Width: Use the default (1). 

Maximum Underhang/Length: Use the default (15). 

Maximum Underhang/Width: Use the default (15). 


9. After completing the unitload parameters, click on OK. 

System Response: TOPS Pro stores your unitload parameters to 


Step 6: Generate Possible Solutions, Make a 

Decision and Save the Analysis to a Folder 

To generate the possible solutions for this analysis, follow these 

instructions: 

1. Click on the Calc button. 

System Response: TOPS Pro uses the defined parameters – carton, 

shipcase and unitload – and generates all possible solutions for the 

analysis. TOPS Pro displays the Analysis View, which is comprised 

of three panes, as pictured below. 

This Analysis View is organized into three panes: 

Shipcase Solution View Pane: This pane, in the top, left portion of 

the screen, displays a graphic of what the selected shipcase solution 

looks like – i.e., how the cartons have been loaded into the shipcases. 

For example, in Figure 23 above, the graphic corresponds to Solution 

1, which is highlighted in the Shipcase Solution List. If you select 

Solution 5 in the Shipcase Solution List, the Shipcase Solution View 

pane displays a graphic for Solution 5, and so on. 

Unitload Solution View Pane: This pane, in the top, right portion of 

the screen, displays a graphic of the selected unitload solution – i.e., 

how the shipcases have been loaded onto the pallet. 


Solution List Pane: This pane, at the bottom of the screen, displays a 

list of the best 50 (if there are 50) solutions generated for the analysis, 

along with a variety of basic information for each solution. 

The Solution List corresponds to the active Solution View pane. If the 

Shipcase Solution View pane is active, the Solution List shows 

shipcase solutions. If the Unitload Solution View pane is active, the 

Solution List shows unitload solutions. 

2. Select a shipcase solution, then click on the Next button. 

System Response: The Analysis View redisplays, as pictured here. 

In addition to the Solution View pane and Solution List pane, notice a 

third pane, the Statistics View pane. This pane, in the top, right portion of 

the screen, displays detailed statistics for the selected unitload solution. 

3. Select a unitload solution. 

4. Click on the Save icon to save the analysis record. 

System Response: The Analysis Save As dialog box appears, as 



Notice three things about this dialog box: 

The Description field allows you to save the analysis with a specific 

title. 

The Folder field provides a drop-down box with a list of folders. You 

can save the analysis into any of these folders; Main Folder is the 

default. The window below the Folder field displays a list of folders 

and analyses that have been saved to a selected folder. 

The New Folder button allows you to create a new folder and add it to 

the database. 

5. In the Description field, enter the name of this analysis. 

6. To create a new folder, click on the New Folder button. 

System Response: The New Folder dialog box appears, as pictured 

below. 

7. Enter the name of the new folder (e.g., John Smith). 


System Response: TOPS Pro saves the new folder to the database 

and redisplays the Analysis Save As dialog box. The new folder (John 

Smith) is now listed as part of the Main Folder. 

9. To save the analysis to the John Smith folder, click on the John Smith 

folder. 


System Response: TOPS Pro saves the analysis to the selected folder. 

Revise Parameters for an Analysis 

To revise any parameters for an analysis that has not yet been generated 

(you've not yet clicked on the Calc button), follow these instructions: 

1. Click on the appropriate icon in the Toolbar. 

2. Use the dialog box to make the necessary changes. 

To revise any parameters for an analysis that has already been generated, 



1. Click on the appropriate icon in the Toolbar. 

2. Use the dialog box to make the necessary changes. 


System Response: TOPS Pro uses your changes to generate a new set 

of solutions. 

Step 7: Email the Stacking Strength Board Combo 

List 

TOPS Pro Version 5.X allows you to access the Stacking Strength Board 

Combo List from an analysis and email it to other users. To use this 

feature, start from the Analysis View and follow these instructions: 

1. From the Windows Toolbar, click on the Stacking Strength button – 

. 

System Response: The Stacking Strength dialog box appears, as 


2. Define stacking strength parameters on the dialog box. 

Note: For detailed instructions, please contact TOPS Pro Technical 

Support. 

3. After completing the stacking strength parameters, click on the OK 

button. 

System Response: The Stacking Strength Results Screen appears, as 

pictured on the next page. 


4. Go to the Windows Toolbar and open the Tools Menu. 

5. Select the Email Stacking Strength option. 

System Response: TOPS Pro automatically launches your email 

application, converts the Stacking Strength Board Combo List to an 

HTML file and attaches it to the email. 

6. Send the email to the appropriate users. 

System Response: TOPS Pro closes the email application and returns 

you to the Stacking Strength Results Screen. 

Step 8: Send the Analysis to Microsoft Word 

TOPS Pro Version 5.X includes a feature that uses a Word template to 

convert an analysis directly to a Microsoft Word file. Each template is 

defined by a number of items – Product, Intermediate Pack, Shipcase and 

Unitload – and a number of views – 3D, Plan, Side and Front. TOPS Pro 

uses these templates to retrieve specific information from an analysis and 

present that information in the form of a Word document. 

Note: TOPS Pro provides a template – Simple.dot – from which you can 

create your own custom Word templates. For instructions, please contact 

TOPS Technical Support. 

To send an analysis to Word, start from the Analysis View and follow 

these instructions: 

1. Go to the Windows Toolbar and open the Export Menu. 

2. Select the Send to Word option. 

System Response: The About MTOPS dialog box appears, as 



3. Select a template from the Template window. 


System Response: TOPS Pro launches Microsoft Word and uses the 

selected template to create a Word file. When Word opens, the active 

document consists of information from the analysis, based on the 

selected template. 


Exercise #2: Perform a Complex 

Analysis 

The second analysis you'll perform is more complex and involves more 

stages, but TOPS Pro makes it an easy process. Suppose you work for an 

oil change service company and need to determine the best way to 

package oil cans, put them on pallets and ship them via truck. 

Note: Because these oil cans are shaped more like bottles, we’ll use bottle 

parameters and refer to the cans as bottles. 

Objective: Find the optimal solution for loading bottles into a carton, into 

a shipcase, onto a pallet and onto a truck. 


The bottles are contained in six-packs. 

Each six-pack unit sits in a tray with dividers. 

Each shipcase contains four six-packs. 

The pallet is a standard pallet. 

The truck is a standard truck. 


through eight simple sets of procedures, in this order: 


2. Define the bottle parameters. 

3. Define the intermediate pack tray parameters. 

Note: Be aware that two types of trays are available – the 

intermediate pack tray (blue icon) and the shipcase tray (yellow icon). 

4. Define the shipcase parameters. 

5. Define the unitload (pallet) parameters. 

6. Define the transit vehicle (truck) parameters. 

7. Generate possible solutions and make a decision. 

8. Design custom styles for the bottles and trays to dress up the display. 





1. Click on the New button to clear any work from the Control Panel. 

2. In the Carton list, click on Bottle. 

System Response: The Carton icon changes to a Bottle icon. 

3. Click on the Bottle button. 

4. In the Intermediate Packer list (blue icon), click on Tray. 

System Response: The Packer icon changes to a Tray icon. 

5. Click on the Tray button. 



8. Click on the Truck button. 

System Response: The Bottle, Tray, Shipper, Pallet and Truck icons 

appear in the Package Design Sequence Area, as pictured below. 

Step 2: Define Bottle Parameters 

To define your bottle parameters, follow these instructions: 

1. Click on the Bottle icon in the Package Design Sequence. 

System Response: The Bottle Parameters dialog box appears, as 



2. Use the following fields to define the specific bottle parameters. Use 

the Tab key to move from field to field. 

Body Shape: Select Rectangular. 

Body Length: Enter 4.25. 

Body Width: Enter 2.63. 

Neck Diameter: Enter 0.7. 


Neck Height: Enter 1. 

Shoulder Height: Enter 2.0. 

Vertical: Check the box to the right of the Height field. 

Notice that as you enter the bottle parameters, the g.o.d. feature illustrates 

how the bottle will look with each added dimension. This feature allows 

you to visually inspect your work and correct any flaws as you go along. 

3. After completing the bottle parameters, click on OK. 

System Response: TOPS Pro stores your bottle parameters to 


Step 3: Define Intermediate Pack Tray Parameters 

To define your intermediate pack tray parameters, follow these 

instructions: 

1. Click on the Tray icon in the Package Design Sequence Area. 

System Response: The Intermediate Pack Parameters dialog box 

appears, as pictured below. 

2. Use the following fields to define the specific tray parameters. Use the 



Case: Use the default (New). 

Style: Select Tray (Shrink Wrap). 

Flute: Use the default (F Flute). 

Sizing: Select Values. 

Values: Enter 4. 

Note: At this point, we don't know the dimensions of the tray, so we 

won't enter any values for length, etc. Instead, we'll select New in the 

Case field, which directs TOPS Pro to design a tray with the 

dimensions to accommodate whatever number of bottles are placed 

inside it. 

Note: The Sizing field gives you two options: (1) define a range of 

bottles to place in a tray or (2) define a set value of bottles to place in a 

tray. Because your bottles are arranged in six-pack units, a set value, 

we'll select Values in the Sizing field and enter 6 in the Values field. 

3. You want the tray to have six-pack dividers, so click on the Dividers 

button. 

System Response: The Dividers dialog box appears, as pictured 

below. 

4. Use the following field to define the specific divider parameters: 

Style: Select (A) 2-Way Cell. 

5. After defining divider parameters, click on OK. 

System Response: TOPS Pro stores your dividers parameters to 

memory and redisplays the Intermediate Pack Parameters dialog box. 

6. After completing the tray parameters, click on OK. 

System Response: TOPS Pro stores your tray parameters to memory 

and redisplays the Control Panel. 


Step 4: Define Shipcase Parameters 

To define your shipcase parameters, follow these instructions: 






Style: Use the default [RSC (FEFCO 0201)]. 

Flute: Use the default (C Flute). 


Note: At this point, we don't know the dimensions of the box, so we 

won't enter values for length, etc. Instead, we'll select New in the Case 

field, which directs TOPS Pro to design a shipcase with the 

dimensions to accommodate whatever number of trays are placed 

inside it. 


Values: Enter 6. 

Note: The Sizing field gives you two options: (1) define a range of 

trays to place in a shipcase or (2) define a set value of trays to place in 

a shipcase. We know we want four six-packs (trays) per case, which is 

a set value, so we'll select Values in the Sizing field and enter 4 in the 

Values field. 





Shipcase Database Option 

As you work through analyses and create various types of shipcases, 

TOPS Pro allows you to save those shipcases to a shipcase database. 

Rather than enter shipcase parameters with each new analysis, this feature 

allows you to use shipcases already defined in the system. 

Notice two things on the Shipcase Parameters dialog box: 

The Case feature includes a Database option, which activates the 

Database feature just below. 

The Database feature tells TOPS Pro to automatically use shipcases 

already set up and stored in the shipcase database. The Database 

feature has two options: 

− All: Tells TOPS Pro to consider all shipcases saved to the 

database when it calculates solutions. 

− Multiple: Opens the Select Items dialog box and allows you to 

select specific shipcases to be used in calculating solutions. 

To use the Multiple option, follow these instructions: 

1. Click on the Multiple button. 

System Response: The Select Items dialog box appears, as pictured 

below. 

Notice two things about this dialog box: 

The window on the left shows a list of shipcases available to be used 

in the calculation. 

The window on the right shows a list of shipcases that have been 

selected to be used in the calculation. 

2. Select a shipcase to be used in the analysis. 



System Response: TOPS Pro adds the selected shipcase to the 

window on the right. 

4. Repeat steps 2 and 3 for each shipcase to be used in the analysis. 

Note: To use all shipcases, click on the Add All button. 

To remove a shipcase from the right-hand window, select the shipcase 

and click on the Remove button. To remove all shipcases from the 

right-hand window, click on the Remove All button. 

5. After selecting the shipcases, click on the OK button. 

System Response: TOPS Pro stores the selected shipcases to memory 

and redisplays the Shipcase Parameters dialog box. 

Step 5: Define the Unitload (Pallet) Parameters 

To define your unitload (pallet) parameters, follow these instructions: 

1. Click on the Pallet icon in the Package Design Sequence Area. 



2. Use the default values to define the specific pallet parameters. Use the 


Note: Be aware that you can define the dimensions for a non-standard 

pallet by using the New Pallet feature. 

3. After completing the unitload parameters, click on OK. 




Step 6: Define Truck Parameters 

To define truck parameters, follow these instructions: 

1. Click on the Truck icon in the Package Design Sequence Area. 

System Response: The Vehicle Parameters dialog box appears, as 


2. Use the default values to define the truck parameters: 

Note: Like the pallets, you can define the dimensions for a nonstandard 

truck by using the New Vehicle feature. 

3. After completing the truck parameters, click on OK. 

System Response: TOPS Pro stores your truck parameters to memory 


Step 7: Generate Possible Solutions and Make a 

Decision 

This step works a little bit differently than in the carton-shipcase-pallet 

scenario. TOPS Pro generates solutions in the same way, but in the first 

scenario, there were two decisions to make in the final analysis – which 

shipcase and unitload solutions are the best way to go. 

In this analysis – bottle-tray-shipcase-pallet-truck – more stages mean 

there are more decisions to make. In this analysis, you'll make a series of 

decisions that take you from one stage in the Package Design Sequence to 

the next. One decision affects the next decision, which affects the next 

decision, and so on. We'll walk through the process one step at a time. 


instructions: 


System Response: TOPS Pro uses the defined parameters – bottle, 

tray, shipcase, pallet and truck – and generates all possible solutions 


for the analysis. TOPS Pro displays the Analysis View, as pictured 

below. 

Let's look at these three panes one at a time: 

Intermediate Pack Solution View: This pane, in the top, left portion 

of the screen, displays a graphic of a selected packer solution – i.e., 

how the tray is designed and utilized. If you select another packer 

solution, this graphic will change accordingly. 

Shipcase Solution View: This pane, in the top, right portion of the 

screen, displays a graphic of the shipcase that corresponds to the 

selected packer solution – how the shipcase is designed and utilized. 

The Shipcase Solution View is driven by the selected packer solution 

and changes in conjunction with the packer solution graphic. 

For example, if you select Solution 2 from the Packer Solution List, 

the packer solution graphic redisplays to reflect the Solution 2 values. 

At the same time, the Shipcase Solution View graphic redisplays to 

reflect Solution 2. For this analysis, we’ll focus on Solution 1. 

Packer Solution List: This pane, at the bottom of the screen, displays 

a list of all packer solutions generated for the analysis. In this 

example, TOPS Pro has generated two packer solutions. 

2. Select a packer solution. 

3. Click on the Next button – – in the Toolbar. 

System Response: TOPS Pro redisplays the Analysis View with three 

new panes, as pictured on the next page. 


As you can see, TOPS Pro has proceeded to the next step in the analysis. 

We've completed the packer stage of the analysis; now we're ready to 

work with the shipcase solutions, which in turn affect the unitload options. 

Let's briefly outline these three panes: 

Shipcase Solution View: This pane displays a graphic of a selected 

shipcase solution – how the shipcase is designed and utilized. 

UnitLoad Solution View: This pane displays a graphic of the 

unitload that corresponds to the selected shipcase solution. It shows 

how the unitload is designed and utilized. 

Shipcase Solution List: This pane displays a list of all shipcase 

solutions generated for the analysis. In this example, TOPS Pro has 

generated five shipcase solutions. 

4. Select a shipcase solution. We’ll go with Solution 1 here. 

5. Click on the Next button – – in the Toolbar. 




Again, TOPS Pro has proceeded to the next step in the analysis. We've 

completed the shipcase stage of the analysis; now we're ready to work 

with the unitload solutions, which in turn affect the truck options. 


UnitLoad Solution View: This pane displays a graphic of a selected 

unitload solution – how the unitload is designed and utilized. 

Vehicle Solution View: This pane displays a graphic of the truck load 

that corresponds to the selected unitload solution. It shows how the 

truck load is designed and utilized. 

UnitLoad Solution List: This pane displays a list of all the unitload 


generated two unitload solutions. 

6. Select the first unitload solution. 

7. Click on Next in the Vehicle View pane. 





completed the unitload stage of the analysis; now we're ready to work with 

the vehicle solutions, which will complete the analysis. 


Vehicle Solution View: This pane displays a graphic of a selected 

truck solution – how the truck load is designed and utilized. 

Vehicle Statistics View: This pane displays detailed statistics for a 

selected vehicle solution. 

Vehicle Solution List: This pane displays a list of all the truck 


generated 20 unitload solutions. 

8. Select a vehicle solution. 

9. Click on the Save button to save the analysis record. 

At this point, now that the analysis is complete, you might want to 

print a hard copy of the information generated for the solution. We'll 

talk about the printing function in the section, "Design the Output from 

an Analysis." 

Make a Decision Using the Quad View 

As the term suggests, the Quad View divides the Analysis View into four 

panes as opposed to three. In this exercise, we'll work through the same 

bottle-tray-carton-pallet-truck analysis using the Quad View. 

Note: The Quad View is available only for analyses with four or more 

stages. 


To generate the possible solutions for this analysis, using the Quad View, 



System Response: TOPS Pro uses the defined parameters – bottle, 

tray, shipcase, pallet and truck – and generates all possible solutions. 

TOPS Pro displays the Analysis View with three panes. 

2. Go to the Menu Bar and open the View menu. 

3. Select Quad Screen. 

System Response: The Analysis View redisplays with four panes, as 


As you can see, TOPS Pro begins with the first stage in the analysis – the 

packer stage – and proceeds in order of the Package Design Sequence. 

Let's briefly outline each of these four panes: 

Intermediate Pack Solution View: This pane, in the top, left portion 

of the screen, displays a graphic view of a packer solution. 

Shipcase Solution View: This pane, in the top, right portion of the 

screen, displays a graphic view of a shipcase solution. This solution 

corresponds to the active packer solution. 

UnitLoad Solution View: This pane, in the bottom, left portion of the 

screen, displays a graphic view of a unit (pallet) load solution. This 

solution corresponds to the active shipcase solution. 


Packer Solution List: This pane, in the bottom, right portion of the 

screen, displays a list of all the packer solutions generated for the 

analysis. In this example, TOPS Pro has generated four packer 

solutions. 

Notice that each pane has a vertical scroll bar at the right edge of the pane. 

At each end of the scroll bar is an arrow – a down arrow at the top of the 

bar and an up arrow at the bottom of the bar. These up and down arrows 

allow you to display a graphic view of each solution for an stage. 

For example, notice that in the Intermediate Pack pane, the title bar of the 

pane indicates that this is the first of four packer solutions (1 of 4). If you 

click on the down arrow on the scroll bar, the Intermediate Pack pane will 

redisplay with a graphic view of the second of the four packer solutions. 

From there, if you click on the up arrow, the first solution will redisplay. 

4. From the Intermediate Pack pane, use the up and down arrows to 

select a unitload solution. You can also select a solution from the 

Packer List. We’ll go with Solution 1. 

5. Click on the Next button in the Toolbar. 

System Response: TOPS Pro stores the packer solution to memory 

and redisplays the Analysis View with new panes, as pictured below. 


completed the packer stage; TOPS Pro now displays panes for the 

remaining stages of the analysis: 

Shipcase View 

UnitLoad View 

Vehicle View 

Shipcase List 


6. From the Shipcase View pane, use the up and down arrows to select a 

shipcase solution. You can also select a solution from the Shipcase 

List. We’ll go with Solution 1. 


System Response: TOPS Pro stores the shipcase solution to memory 

and redisplays the Analysis View with new panes, as pictured below. 


completed the shipcase stage; TOPS Pro now displays panes for the 

remaining stages of the analysis: 

UnitLoad View 

Vehicle View 

UnitLoad List 

8. From the UnitLoad View pane, use the up and down arrows to select a 

unitload solution. You can also select a solution from the Unitload 

List. We’ll go with Solution 1. 


System Response: TOPS Pro stores the unitload solution to memory 

and redisplays the Analysis View with new panes, as pictured on the 

next page. 



completed the unitload stage; TOPS Pro now displays panes for the 

remaining stage of the analysis: 

Vehicle Solution View 

Vehicle Statistics View 

Vehicle Solutions List 

10. From the Vehicle View pane, use the up and down arrows to select a 

vehicle solution. You can also select a solution from the Vehicle List. 

We’ll go with Solution 1. 


System Response: TOPS Pro stores the vehicle solution to memory 


Step 8: Design Custom Styles for the Bottles and 

Trays to Dress Up the Display. 

In this last step, we’ll design custom styles for the bottles and trays to 

dress up the on-screen display. Instead of generic bottles and trays, we’ll 

give them a more realistic design. We’ll make a generic bottle look like 

an oil can and give the tray a large display area on the front side. We’ll 

design these custom styles using the Create A Shape Yourself (CASY) 

system. 

Design a Custom-Shaped Bottle 

To design a custom-shaped bottle to make it look like an oil can, start 

from the Control Panel and follow these instructions: 


1. Click on the CASY Primary Package icon – – in the Toolbar. 

System Response: The CASY Primary Package Screen appears, as 


2. Use your mouse to click on the left edge of the work unit (on the left) 

and mark off four distinct sections, as pictured below. 

Notice that the display unit shows four clearly defined sections. 

3. One by one, click on each marker on the left edge of the work unit and 

drag it toward the center of the unit; leave the last marker (flush 

bottom) where it is. Use the figure on the next page as a guide. 

When you drag a marker from the left, the point on the opposite side 

moves toward the center as well to give the figure symmetry. This 

defines the overall shape of the sections that comprise the oil can. 


When you’ve moved the markers, the work unit should look similar to 

the one pictured below. 

4. At this point, you can fine-tune the shapes of each section of the oil 

can if you wish. In this exercise, we’ll go with the default primary 

shape (Round) for each section of the oil can. The can should look 

like the one pictured on the next page. 

Note: TOPS Pro allows you to select a primary shape for a selected 

section of a work unit. Right-click on a section of the work unit, then 

use the small menu to select a Primary Shape. 

5. Next, we'll position the spout off-center, flush to the right side of the 

oil can. Click on the center marker for the spout section and drag it to 

the right; use the figure below as a guide. When you’ve dragged the 

first section flush right, the work unit will redisplay as pictured on the 

nest page. 


6. Notice that in Figure 50 above, there’s a disjointed space where the 

spout section meets the neck section of the can; it needs a smoother 

transition. CASY allows you to smoothly transition from one section 

to another when one section is off-center. 

Right-click in the neck (second) section on the work unit. 

System Response: The small menu appears. 

Select the Primary Shape option. 

System Response: The submenu appears. 

Select the TransTop option. 

System Response: The work unit redisplays with the spout and neck 

sections of the can joined seamlessly together, as pictured below. 


At this point, the design is complete. If you want, you can assign colors 

and bitmaps to individual sections of the can. 

7. If you’re satisfied with the oil can, name it and save it to the database. 

In this exercise, we’ll name it OILCAN. As you work with primary 

packs, the oil can will be included in the list of CASY-style options. 

Design a Custom-Shaped Tray 

To design a custom-shaped tray, start from the Control Panel and follow 

these instructions: 

1. Click on the CASY Shipcase/Tray icon – – in the Toolbar. 

System Response: The CASY Shipcase/Tray Screen appears, as 


2. When the CASY Shipcase/Tray Screen opens, the front side of the unit 

is active by default, so we’ll work with that side first. The front needs 

six markers along its top edge, which we’ll use to design the display 

window. The top left and top right corners serve as two of the 

markers. 

One by one, click on each marker on the top edge of the tray to 

position the other four markers. The work unit, with six markers 

across the top edge, should look like the one pictured on the next page. 


3. For markers 3 and 4, drag the markers downward; use the figure below 

as a guide. When you’ve moved these markers into the right positions, 

the work unit should look like the one pictured below. 

4. Now that the display window on the front side of the tray is complete, 

repeat the same process to design a display window for the back side 

of the tray. 

5. On the left and right sides of the tray, we want to create holes to serve 

as handles for the tray. To create a hole in the left side of the tray, 

click on the Left icon on the Toolbar. 

System Response: The CASY Shipcase/Tray Screen redisplays with 

work unit representing the left side of the tray. 


6. Right-click inside the work unit. 

System Response: A small menu appears. 

Select the Create Hole option. 

System Response: The system inserts a box, which represents the 

hole, on the face of the work unit. 

Resize the box (hole) to the appropriate size and move it near the top 

edge of the work unit. The left side of the tray should look similar to 

the one pictured below. 

7. Now that the hole on the left side of the tray is complete, repeat the 

same process to design a hole for the right side. 

8. CASY allows you to select and insert a bitmap onto any side of the 

tray. To insert a bitmap, select a side (front, back, left or right) to 

make it active. 

Right-click inside the work unit. 

System Response: The small menu appears. 

Select the Insert Bitmap option. 

System Response: A dialog box appears with a list of bitmap files. 

Select the bitmap file you want to insert and click on the Open button. 

System Response: The system inserts the selected bitmap onto the 

active side of the tray. You can resize the bitmap as you like and drag 

it to any position on the active side. 

In this exercise, we’ll insert a TOPS bitmap on the left and right sides 

of the tray. After all the design elements are complete, the tray should 

look similar to the one pictured on the next page. 


9. If you’re satisfied with all the elements of the tray, be sure to give it a 

name and save it to the database. In this exercise, we’ll name it 

TRAY001. Now, when you’re working with intermediate packers, 

this tray style will be available in the list of CASY-style options. 

Display CASY Styles in the Analysis 

As you’re working through an analysis, TOPS Pro gives you the capability 

to display your work using the custom-shaped bottles, trays, etc. you 

designed with the CASY system. Let’s go back to the analysis and the 

first Analysis View in the process, as pictured below. 


To display CASY designs in the analysis, follow these instructions: 

1. Click on the Show CASY icon – – in the Toolbar. 

System Response: This turns on the Show CASY mode. 

2. Click on the Modify Primary Pack Parameters icon in the Toolbar. 

System Response: The Bottle Parameters dialog box appears. 

3. From the CASY Style drop-down list, select OILCAN.TPR, which is 

the file that represents your oil can. 

4. Click on OK. 

System Response: The Analysis View redisplays with the generic 

bottles now shown as CASY oil cans, as pictured below. 

5. Click on the Modify InterPack Parameters icon in the Toolbar. 

System Response: The Intermediate Pack Parameters dialog box 

appears. 

6. From the CASY Style drop-down list, select TRAY001.TSC, which is 

the file that represents your tray for display. 


System Response: The Analysis View redisplays with the generic 

trays now shown as CASY die-cut trays, as pictured on the next page. 


At this point, the exercise is complete. 


Exercise #3: Perform a Knockdown 

Analysis 

One frequently used analysis is the knockdown (KD) analysis, in which a 

box has been collapsed flat. In a KD analysis, you'll usually take a bundle 

of collapsed boxes and load them onto a pallet. The dimensions of the box 

have obviously changed. TOPS Pro allows you to account for the 

knockdown by entering the dimensions of a box after it has been collapsed 

flat. 

Note: The Knockdown button, located on the Carton Parameters dialog 

box, will automatically calculate these dimensions for you. However, the 

Knockdown button is used only for RSC-style boxes. 

Objective: Find the optimal solution for loading bundles of collapsed 

boxes onto a pallet after one or more boxes have been collapsed. 


Each KD carton (box) measures 16.75 inches long, 14.5 inches wide 

and 0.5 inches high. 

Each bundle is configured as a shipcase that contains 20, 25 or 30 

collapsed boxes. 

The pallet is non-standard, which means you'll design a new pallet 

tailored to your needs. 




2. Define the carton (KD box) parameters. 

Note: Be aware that two types of cartons are available – the box 

carton (green icon) and the intermediate pack carton (blue icon). 

3. Define the shipcase (bundle) parameters. 


5. Generate possible solutions and make a decision. 





1. Click on the New button to clear any work from the Control Panel. 

2. Click on the Box Carton (green icon) button. 



System Response: The Carton, Shipper and Pallet icons appear in the 

Package Design Sequence area of the panel, as pictured below. 

Step 2: Define Carton (KD Box) Parameters 

To define your carton (KD box) parameters, follow these instructions: 

1. Click on the Box Carton icon in the Package Design Sequence Area. 

System Response: The Carton Parameters dialog box appears, as 


This dialog box allows you to enter parameters for a collapsed box. 

2. Use the following fields to define the KD box parameters. Use the 


Length: Enter 16.75. 

Width: Enter 14.5. 

Height: Enter 0.5. 


3. After completing the carton parameters, click on OK. 

System Response: TOPS Pro stores your carton parameters to 


Step 3: Define Shipcase (Bundle) Parameters 

To define your shipcase (bundle) parameters, follow these instructions: 




This dialog box allows you to define the parameters of your shipcase in a 

very precise, thorough manner. In addition to the general dimensions 

outlined in the objective of this analysis, you'll also define these 

parameters: 

The shipcase is a new case. 

The style is bundle (invisible). 

Shipcase dimensions are measured from the outside. 

For sizing purposes, maximum cartons along the length, width and 

depth of the shipcase are 1, 1 and 100, respectively. 




Style: Select Bundle (Invisible). 

Dimensions: Use the default (Outside). 

Vert: Use the default (Height). 


Values: Enter 20, 25 and 30. 


3. Click on the Options button. 

System Response: The Shipcase Options dialog box appears, as 


This dialog box allows you to further define the sizing of the shipcase 

(bundle). 

4. Use the following fields to define the sizing of the shipcase: 

Max Cartons along Length/Cartons: Enter 1. 

Max Cartons along Width/Cartons: Enter 1. 

Max Cartons along Height/Cartons: Enter 100. 

5. After completing the sizing parameters, click on OK. 

System Response: TOPS Pro stores your sizing parameters to 

memory and redisplays the Shipcase Parameters dialog box. 




Step 4: Define Unitload (Pallet) Parameters 

In this exercise, let's assume that your bottling company needs to send 

palletized knockdowns to another location. Your company uses a unique, 

non-standard pallet not included in the TOPS database. Therefore, we'll 

use TOPS Pro to create a unique pallet with the following characteristics: 

The pallet measures 50 by 50 inches, and has a height of 5 inches. 

The pallet weighs 65 pounds. 

The pallet is a stringer pallet with flush alignment and single-face 

construction. 


The deck board dimensions are standard for a stringer pallet. 

The pallet has a maximum overhang of 3 inches along the height and 

width. 

To define your unitload (pallet) parameters, follow these instructions: 

1. Click on the Pallet icon. 



2. Use the following fields to define maximum overhang: 

Maximum Overhang Length: Enter 3. 

Maximum Overhang Width: Enter 3. 

3. Click on the New Pallet button. 

System Response: The Define Pallet dialog box appears, as below. 


Notice that the Define Pallet dialog box allows you to design your pallet 

in a very precise manner: 

The Style options allow you to select the type of pallet you want to 

build. 

The Size options allow you to enter the length, width, height and 

weight of the pallet. 

The Deck Boards options allow you to enter dimensions of the 

pallet's deck boards, how much space is between the deck boards, how 

high, how many, etc. 

4. Use the following fields to define the pallet parameters. Use the Tab 

key to move from field to field. 

Style: Use the default (Stringer). 

Alignment: Use the default (Flush). 

Description: Enter Test Pallet. 

Construction: Use the default (Single Face). 




Weight: Enter 65. 

Outside deck board width: Use the default (7). 

Number of inside deck: Use the default (5). 

Inside deck board width: Use the default (5). 

Deck board height: Use the default (1). 

Stringer Width: Use the default (2). 

5. After completing the pallet parameters, click on OK. 

System Response: TOPS Pro stores your pallet parameters to 

memory and redisplays the UnitLoad Parameters dialog box. 

At this point, let's say you want all the knockdowns oriented the same 

way on the pallet – a one-block pattern. (In a two-block pattern, the 

knockdowns are oriented in two ways, and so on.) Because you want 

to see only a one-block solution, you need to tell TOPS Pro to 

eliminate all other possibilities. 

6. Click on the Options button. 

System Response: The UnitLoad Options dialog box appears, as 



Notice a couple of things about the UnitLoad Options dialog box: 

The Pattern Styles section provides a list of all types of patterns you 

might want to see. To select a pattern style, you click on the box next 

to that style, and an "" marks that style as selected. To de-select a 

pattern style, click on the box again, and the box is cleared. 

When you select a pattern style, the g.o.d. window in the bottom, right 

corner of the screen displays a visual of what the selected pattern style 

looks like. 

7. You want to see only a one-block pattern, so select 1 Block. If you see 

any options marked with a "" as selected, and be sure to de-select 

those options. 


System Response: TOPS Pro stores your unitload options to memory 

and redisplays the UnitLoad Parameters dialog box. 

9. If all your unitload parameters are correct, click on OK. 




Step 5: Generate Possible Solutions and Make a 

Decision 


instructions: 


System Response: TOPS Pro uses the defined parameters – carton, 

shipcase and unitload – and generates all possible solutions for the 

analysis. TOPS Pro displays the Analysis View with three different 

panes, as pictured below. 

Let's look at these three panes one at a time: 

Shipcase Solution View: This pane, in the top, left portion of the 

screen, displays a graphic of what a selected shipcase solution looks 

like – i.e., how the collapsed boxes are bundled. If you select another 

solution from the Shipcase Solution List, this graphic will change 

accordingly. 

UnitLoad Solution View: This pane, in the top, right portion of the 

screen, displays a graphic of the unitload that corresponds to the 

selected shipcase solution. It shows how the bundles are configured 

on the pallet. The UnitLoad Solution View is driven by the selected 

shipcase solution and changes in conjunction with the Shipcase 

Solution View. 

For example, if you select Solution 2 from the Shipcase Solution List, 

the Shipcase Solution View will redisplay to reflect the Solution 2 

values. At the same time, the UnitLoad Solution View will redisplay 

to reflect Solution 2. 


Shipcase Solution List: This pane, at the bottom of the screen, 

displays a list of all shipcase solutions generated for the analysis. In 

this example, TOPS Pro has generated three shipcase solutions. 

Select a shipcase solution. 



new panes, as pictured below. 

Notice that TOPS Pro has proceeded to the next step in the analysis. 

We've completed the shipcase stage of the analysis; now we're ready to 

work with the unitload solutions, which will complete the analysis. 

All three panes work in conjunction with one another. Let's briefly outline 

these three panes: 

UnitLoad Solution View: This pane displays a graphic of what a 

selected unitload solution looks like – i.e., how the knockdowns are 

loaded onto the pallet. 

UnitLoad Statistics View: This pane displays detailed statistics for a 

selected solution. 

UnitLoad Solution List: This pane displays a list of all the solutions 

generated for the analysis. For this analysis, TOPS Pro has generated 

two solutions for the given shipcase and unitload parameters. 

For each solution, this pane displays 15 items of basic information – 

case weight, volume, vertical dimension, etc. – which appear in 15 

columns across the pane. 

4. Select a unitload solution. 


5. Click on OK in the UnitLoad View pane. 

System Response: TOPS Pro redisplays the Control Panel. 

6. Click on the Save button to save the analysis record. 

At this point, now that the analysis is complete, you might want to print a 

hard copy of the information generated for the solution. We'll talk about 

the printing function in the next section, "Design the Output From an 

Analysis." 


Exercise #4: Design the Output From 

an Analysis 

The TOPS Pro software provides much flexibility in the way you design 

and print analysis output. After you've decided on your solutions, you're 

ready to print a hard copy that shows the information that went into your 

analysis. 

You'll design the layout of the printout, then decide what type of 

information will be included and how that information will be presented 

(different graphical views, statistics, etc.). In this exercise, we'll design 

the output to have the following characteristics: 

The output will have a Quad Split page layout. 

The heading will read "Exercise #2: Complex Analysis." 

The four areas of the printout will show graphics of the Case 3D View, 

the Unitload Plan View, the UnitLoad Dual Plan and the Vehicle 3D 

View. 

The bottom of the printout will show sample text. 

To design the output for an analysis, you'll start from the Control Panel 

and work through two simple sets of procedures, in this order: 

1. Define print parameters. 

2. Add text or images to the printed output. 

Step 1: Define Print Parameters 

To define print parameters, start from the Control Panel and follow these 

instructions: 

1. Open the analysis record you created for Exercise #2: Perform a 

Complex Analysis. 

2. Go to the Menu Bar and open the File menu. 

3. Select Print Preview, then select Analysis. 

System Response: The Print Parameters dialog box appears, as 



Let's take a brief overview of the Print Parameters dialog box: 

The Page Layout section allows you to select one of eight possible 

page layouts: 

The Full Page layout allows you to select only one area of the 

analysis to print. 

The Horizontal Split and Vertical Split layouts allow you to select 

two areas of the analysis to print. 

The 3 Way Bottom, 3 Way Top, 3 Way Left and 3 Way Right 

layouts allow you to select three areas of the analysis to print. 

The Quad Split layout allows you to select four areas of the analysis 

to print. 

The Heading field allows you to enter the text of the heading that you 

want to appear at the top of the printout. 

The Areas 1, 2, 3 and 4 fields allow you to select the area(s) of the 

analysis from which you want to print information. 

Note: Be aware that the number of areas available to select from 

depends on the page layout you selected. For example, if you selected 

the Horizontal Split layout, which contains two sections, you'll be able 

to select from only two areas. 

The Notes field allows you to enter the text of any notes that you want 

to appear at the bottom of the printout. 


The Show Additional Notes fields allow you to enter information 

such as Label Format, Test Weight and Package Quantity. 

4. Use the following fields to enter print parameters. Use the Tab key to 

move from field to field. 

Page Layout: Select Quad Split. 

Heading: Enter "Exercise #2: Complex Analysis." 

Area 1: Select Case 3D View. 

Area 2: Select Unitload Plan View. 

Area 3: Select UnitLoad Dual Plan. 

Area 4: Select Vehicle 3D View. 

Notes: For exercise purposes, enter the following text: "This is 

where you'll enter any text you want to appear at the bottom of 

your printout." 

5. If all your print parameters are correct, click on OK. 

System Response: TOPS Pro displays the Print Preview panel, as 


Notice the following things about the Print Preview panel: 

The heading reads "Exercise #2: Complex Analysis" and includes 

today's date. The heading also includes a title, if you specified a title. 

Area 1 displays a graphic of the Case 3D View. 

Area 2 displays a graphic of the Unitload Plan View. 


Area 3 displays a graphic of the UnitLoad Dual Plan. 

Area 4 displays a graphic of the Vehicle 3D View. 

At the bottom of the printout, the Notes section displays the sample 

text you entered. 

The Zoom button allows you to magnify the panel and get a closer, 

more detailed look at the output. 

The Print button sends the output to the printer. 

The Email button allows you to send the analysis report to another 

person via email. 

6. To print the output, click on the Print button. 

System Response: TOPS Pro sends the print preview output to the 

printer. 

Step 2: Add Text or Images to Printed Output 

After you've designed and generated your analysis output, TOPS Pro 

allows you to add text or graphic images to the output before you print it. 

This is a very easy process that allows you to customize and enhance the 

output's presentation. 

To add text and images to the output, start from the Print Preview panel 

and follow these instructions: 

1. Click on the Zoom button. 

System Response: TOPS Pro magnifies the Print Preview panel. 

2. Click on the area of the output where you want to enter text. 

System Response: TOPS Pro displays a four-cornered entry field 

with the cursor positioned inside the field. Notice that you can "drag" 

the entry field to any position on the screen. 

3. In this exercise, enter text as follows: 

In the first quad (top left), click above the graphic and enter this 

text: "Bottles into a Case." 

In the second quad (top right), click above the graphic and enter 

this text: " Cases on a Pallet – Plan View." 

In the third quad (bottom left), click above the graphic and enter 

this text: "Cases on a Pallet – Rotated Layers." 

In the fourth quad (bottom right), click above the graphic and enter 

this text: "Loaded Pallets on a Truck." 


4. Drag the text fields so that they're centered at the top of each quad, 

above the graphics. 

Now that you've entered your text, suppose you want to add a graphic 

image to the fourth quad (bottom right). 

5. Go to the Menu Bar and open the Edit Menu. 

6. Select Paste Pict From File. 

System Response: The Select File dialog box appears, as pictured 

below. 

Notice that this dialog box displays a list of bitmap files. 

7. Select the tops.bmp file and click on OK. 

System Response: The Print Preview panel redisplays with the 

selected TOPS bitmap file inserted into the output. 

8. Drag the image to the bottom, right corner of the fourth quad. 

9. If all your text and graphics are correct, click on the Print button. 

System Response: TOPS Pro sends the analysis output to the printer. 

For a hard copy of this output, see the last page of this Tutorial Guide. 

10. Click on the Close button. 

System Response: TOPS Pro asks if you want to save your changes. 

11. Click on Yes. 

System Response: TOPS Pro prompts you to enter a filename to be 

saved. 

12. Enter the name of this file and click on OK. 

System Response: TOPS Pro redisplays the Control Panel. 


Exercise #5: Publish an Analysis to 

the Web or Network 

TOPS Pro allows you to publish the results of an analysis to the Web or to 

a local network, thus allowing other people to view the analysis. With the 

Publish Analysis feature, analyses are collected into albums, which are 

created by the user to logically organize one or more analyses. 

To publish an analysis to the Web or network, start from the Control Panel 

and follow these instructions: 

1. Go to the Menu Bar and open the File Menu. 

2. Select the Publish Analysis option, then select either the To Web or To 

Network option. 

System Response: The Publisher dialog box appears in one of two 

forms, as pictured below. 


The Publisher dialog box is organized into the following sections: 

Publish Profile: A profile contains one or more selected analyses; the 

profile is published to the Web or network. This section allows you to 

create a new profile or select an existing profile, as well as specify 

whether the profile is published to the Web or local network. 

Site: Allows you to specify the location to which the profile will be 

published. 

− With the Web/Internet option selected, the Site section prompts 

you to enter information for Address, Remote Path, User Name 

and Password. 

− With the Local Network option selected, the Site section prompts 

you to enter a destination path. 

Album: Allows you to create a new album or select an existing album 

to which the selected analysis will be stored. 

Analysis: Allows you to select and add one or more analyses to be 

published as part of the profile. 

File Transfer Status: Displays a list of FTP transactions (when 

publishing a profile to the Web). 

3. In the Profile Name field, use the drop-down list to select the profile 

that will be used to publish the analysis. 

Note: To create a new profile, click on the New Profile button and 

enter the name of the new profile in the Profile Name field. 


To remove a profile, select the profile from the drop-down list, then 

click on the Remove Profile button. 

4. In the Site section, enter information for one of two options: 

− If publishing to the Web, enter the Address, Remote Path, User 

Name and Password. 

Note: The Show Options button displays three additional 

Web/Internet-related fields. 

− If publishing to a local network, browse for and select the path. 

Note: For specific Site information, please contact your IT 

Department. 

5. After entering Site information, click on the Connect button. 

System Response: TOPS Pro establishes a connection to the 

specified site, then populates the Album section with a list of existing 

albums stored on the site. 

6. In the Album section, select the existing album that contains the 

analysis to be published. 

Note: To create a new album, click on the New Album button and 

enter the name of the new profile in the Profile Name field. 

To remove an album from the site, select the album from the list, then 

click on the Remove Album button. 

7. In the Analysis section, go to the “Available for Publishing” list, select 

the analysis you want to publish, then click on the Add button. Repeat 

this step for each analysis you want to add to the profile. 

Note: To remove an analysis from the profile, select the analysis in 

the “Existing Analysis is Selected” list and click on the Remove 

button. 

System Response: TOPS Pro retrieves images from the selected 

analysis, converts the images to XML and HTML files, and sends the 

files to the server. 

Note: When publishing to the Web, TOPS Pro displays a log of FTP 

transactions in the File Transfer Status window. If there is an error 

publishing to the Web, this log provides information that might 

identify the problem. 

8. To save the profile, click on the Save Profile button. 

System Response: TOPS Pro saves the profile, including all Site 

information, to the database. 


Exercise #6: New CASY Features 

The CASY function now includes two new primary shapes – Round 

Rectangle and Trigger Top – and five new shape functions – Match Top, 

Match Bottom, Match Both, Pinch Top and Pinch Bottom. 

New Primary Shape – Round Rectangle 

The Round Rectangle can be used to design containers like an ice cream 

box. Start from the CASY Primary Package Screen and follow these 

instructions: 

1. Right-click inside the work unit. 


2. Select the Primary Shape option, then select the Round Rectangle 

option. 

System Response: The work unit in the Edit View Display Area 

converts to a Round Rectangle shape, as pictured below. 

New Primary Shape – Trigger Top 

The Trigger Top can be used to design containers like a Windex bottle. 

Start from the CASY Primary Package Screen and follow these 

instructions: 

1. Click on the edge of the work unit to create a section marker. (To use 

the Trigger Top shape, the work unit must have a top section and a 

bottom section.) 

2. Right-click inside the top section of the work unit. 


3. Select the Primary Shape option, and then select the Trigger Top 

option. 

System Response: The cylinder in the Edit View Display Area 

converts to a Trigger Top shape, as pictured on the next page. 


New Shape Function – Match Top 

The Match Top function makes the top of one section conform to the 

shape of the section directly above it. For example, in the figure below 

the work unit has a rectangular bottom section and a round top section. 

1. Right-click on the bottom section of the work unit. 


2. Select the Shape Function option, then select the Match Top function. 

System Response: In the bottom section of the work unit, the top 

portion of the rectangle becomes rounded to match the section above 

it, as pictured below. 


New Shape Function – Match Bottom 

The Match Bottom function makes the bottom of one section conform to 

the shape of the section directly below it. For example, in the figure 

below the work unit has a rectangular top section and a round bottom 

section. 

1. Right-click on the top section of the work unit. 


2. Select the Shape Function option, then select the Match Bottom 

function. 

System Response: In the top section of the work unit, the bottom 

portion of the rectangle becomes rounded to match the section below 

it, as pictured below. 

New Shape Function – Match Both 

The Match Both function transforms both the top and bottom portions of a 

work unit section. For example, the figure below shows a work unit with 

three sections – a round top, an oval middle and a rectangular bottom. 

The Match Both function will transform the oval middle section to match 

both the round top section and the rectangular section. 


1. Right-click on the middle section of the work unit. 


2. Select the Shape Function option, then select the Match Both function. 

System Response: The oval (middle) becomes rounded where it 

meets the round top; the oval (middle) takes on a rectangle shape 

where it meets the rectangular bottom, as pictured below. 

New Shape Function – Pinch Top 

The Pinch Top function transforms a section of any shape and gives its top 

edge a pinched shape. The Pinch Top function is useful for designing 

tubes of gel, sunscreen, etc. In the figure below the work unit has a round 

top section. 

1. Right-click on the top section of the work unit. 


2. Select the Shape Function option, then select the Pinch Top function. 

System Response: The work unit transforms with a pinched top, as 



New Shape Function – Pinch Bottom 

The Pinch Bottom function transforms a section of any shape and gives its 

bottom edge a pinched shape. The Pinch Bottom function is useful for 

designing tubes of toothpaste, etc. In the figure below the work unit has a 

round bottom section. 

1. Right-click on the bottom section of the work unit. 


2. Select the Shape Function option, then select the Pinch Bottom 

function. 

System Response: The work unit transforms with a pinched bottom, 

as pictured below. 


Exercise #6: Design a Mixed Pallet 

TOPS Pro features a module known as MixPro Pallet, which allows you to 

design a pallet for display with any number of different size boxes. In this 

exercise, we're loading a pallet for shipment to a warehouse store, where 

the pallet will be displayed directly on a busy aisle. This mixed pallet 

load includes several shipcases of snack foods – 15 cases of chocolate 

bars, 32 cases of peanut bars and 30 cases corn chips, all of which have 

different shipcase dimensions. 

To design a pallet for display, you'll start from the Control Panel and work 


1. Select and define a pallet. 

2. Create new shipcases. 

3. Add the shipcases to the pick list. 


Step 1: Select and Define a Pallet 

To select and define a pallet, start from the Control Panel and follow these 

instructions: 

1. Go to the Toolbar and click on the MixPro Pallet Design Editor icon – 

. 

System Response: The MixPro Screen appears, as pictured below. 


System Response: The Pallet Parameters dialog box appears, as 



3. Use the following fields to define the pallet parameters: 

Pallet: Use the default (GMA [Notched]). 

Length Overhang: Use the default (0). 

Width Overhang: Use the default (0). 

Maximum Height (Including Pallet): Enter 56. 

Weight: Use the default (0). 

Step 2: Create New Shipcases 

Suppose you want to load some specific type shipcases, but they're not 

included in the shipcase list. MixPro allows you to create new shipcases 

to meet your needs. To create new shipcases, follow these instructions: 

1. Look at the shipcase list and decided which items you want to load 

onto the pallet. In this exercise, we want the mixed pallet load to 

include chocolate bars, peanut bars and corn chips. 

Notice that the initial shipcase list does not include any of these items. 

In this case, MixPro allows you to create new shipcases for these 

items. 

To create a new shipcase, click on the New button. 

System Response: The Define Shipcase dialog box appears, as 



2. Use the following fields to define the three shipcases: 

Chocolate Bars Shipcase 

Shipcase: Enter Chocolate Bars. 




Peanut Bars Shipcase 

Shipcase: Enter Peanut Bars. 




Corn Chips Shipcase 

Shipcase: Enter Corn Chips. 




System Response: The MixPro Screen redisplays with the name of 

the new shipcase included in the shipcase list. 

Step 3: Add Shipcases to the Pick List 

Once your shipcase list is complete, you're ready to add items to the pick 

list. The pick list allows you to select items for loading onto the pallet. 

To add shipcases to the pick list, follow these instructions: 

1. Select an item from the shipcase list and click on the Add button, or 

double-click on the item. 

System Response: MixPro adds the selected item to the pick list. 

2. Repeat this step for each item you want to select to the pick list – 

chocolate bars, peanut bars and corn chips. 

Step 4: Load Cases Onto the Pallet 

To load cases onto the pallet, follow these instructions: 

1. From the pick list, double-click on an item to be loaded onto the pallet. 

In this exercise, we’ll select the chocolate bars first. 

System Response: A graphic of the selected shipcase appears in the 

g.o.d. (graphic online display) window, located in upper left corner of 

the data display window, as pictured on the next page. 


2. To load the item onto the pallet, click on the image of the shipcase in 

the g.o.d. window and drag it onto the pallet. 

System Response: The system copies an image of the shipcase to the 

pallet area, as pictured below. 

In the figure above, you can see that the shipcase is sitting a few inches 

from the closest edge of the pallet. We want the case to sit flush in the top 

left corner of the pallet. The Snap feature allows you to position the 

shipcase flush against any part of the pallet you choose. 

3. Click on the red X to activate the Snap feature, then click on the 

button. Click on the shipcase and drag it to the top left corner of the 

pallet. 

System Response: The shipcase moves flush into the corner of the 

pallet. 


4. We've loaded the first of 15 cases of chocolate bars onto the pallet. To 

complete the unitload, follow these guidelines: 

Tips for Working with Cases on a Pallet 

To add a second case to the pallet, hold down the Shift key and click 

on the first shipcase. To place the second case on top of the first case, 

Shift and click on top of the first case. To place the second case to the 

side of the first case, Shift and click on the side of the first case. 

If you’ve loaded a column, row or layer of cases on the pallet, you can 

add another column, row or layer with one click. For example, to add 

a layer of cases, hold down the Shift key and click on the top of the 

first layer. The system adds another layer on top of the first layer. To 

remove a layer of cases, hold down the Alt and Shift keys 

simultaneously and click on the layer. 

To remove (or delete) one or more cases from the pallet, click on the 

case(s) and drag it off the backside of the pallet (to the left). The 

case(s) completely disappear from the display. 

To temporarily remove one or more cases from the pallet – you want 

to load it back later – click on the case(s) and drag it off the front side 

of the pallet (to the right). The case(s) remain in view on the display. 

Use the Layer button to have MixPro calculate optional patterns for 

the selected shipcase. 

Using these guidelines, continue to load cases until you’ve loaded 15 

cases of chocolate bars to the pallet, forming a wall along the backside of 

the pallet. Your unitload will look similar to the one pictured below. 


5. To begin adding the next item onto the pallet (the peanut bars), select 

it from the pick list. The case pictured in the g.o.d. window changes to 

the newly selected case. 

Complete the mixed pallet load until the unitload contains the 

following items: 

15 cases of chocolate bars 

32 cases of peanut bars 

30 cases of corn chips 

When you’ve finished loading the three different shipcases, the 

unitload will look similar to the unitload pictured below. 

6. Now that all the shipcases are loaded onto the pallet, you can now use 

the alignment buttons to position the unitload on the pallet as you like 

– to the top, bottom, left, right, etc. You can also display the labels on 

the various shipcases. 

Note: The MixPro alignment feature works a little differently than in 

TOPS. In MixPro, the alignment moves the entire load; you cannot 

select individual cases to align. 

7. When your mixed pallet load is aligned the way you want it, you’re 

ready to work with the Print Preview feature, tailor the report the way 

you like, then print it. 

8. Before closing the MixPro feature, be sure to give this mixed pallet 

file a name and save the file. 


Exercise #8: Design a Mixed Tray 

TOPS Pro features a module known as MixPro Tray, which allows you to 

design a mixed-product tray for display with different size packages in the 

tray. For example, suppose you’re loading trays to be displayed in a 

grocery store, where the tray will be displayed directly on a busy aisle. 

In this exercise, the mixed tray includes several different items of nutrition 

supplements – cans of protein powder, bottles of Gatorade and energy 

bars, all of which have different product dimensions. MixPro Tray allows 

you to easily load and place all types of packages onto a tray. These trays 

can then be saved and used in MixPro Pallet to create a mixed pallet for 

display. 

To design a pallet for display, you'll start from the Control Panel and work 


1. Select and define a tray. 

2. Create new packages. 

3. Add the packages to the pick list. 

4. Load the items onto the tray. 

Step 1: Select and Define a Tray 

To select and define a tray, start from the Control Panel and follow these 

instructions: 

1. Go to the Toolbar and click on the MixPro Tray Design Editor icon – 

. 

System Response: The MixPro Tray Editor appears, as pictured here. 


Notice the following features on the MixPro Tray Editor: 

Shipcase Button: Allows you to select a tray template. 

Package List: Displays a list of packages (or objects) that you can 

add to the pick list for loading onto the tray. 

Add Button: Moves a selected item from the package list to the pick 

list. 

Delete Button: Deletes a selected item from the package list. 

New Button: Opens the Define Package Info dialog box and allows 

you to create a new package/object. Use this function if the package 

list does not include the package you need. 

Remove Button: Removes a selected package from the pick list. 

Modify Button: Opens the Define Package Info dialog box, which 

allows you to modify a newly created package/object. 

Note: The Modify function applies only to packages created in 

MixPro Tray. You cannot modify packages created in TOPS Pro. 

Also, you cannot modify a package that’s already placed onto the tray. 

Pick List: Displays a list of packages you’ve selected from the 

package list. These packages can be loaded onto the tray. The pick 

list also tracks the following information for each type of package: 

number of packages, length, width and height. 

Tray Display Window: Displays an image of the tray and allows you 

to drag packages onto the tray. 

Snap Toolbar: Allows you to move the assortment of packages flush 

to any corner or side of the tray. 

In this exercise, we’ll create a mixed tray that consists of the following 

ArmorAll products: 

ArmorAll spray bottles 

ArmorAll cloth packets 

The first step in this process is to create a new tray designed to hold these 

products. We’ll design the tray based on a template designed in CASY. 

From the MixPro Tray Editor, follow these instructions: 

2. Click on the Shipcase button. 

System Response: The Select ShipCase dialog box appears, as 



2. From the Select Shipcase dialog box, click on the New button. 

System Response: The Define Shipcase dialog box appears, as 


3. Use the following fields to define the tray parameters: 

Shipcases: Enter ArmorAll. 




4. After completing the tray parameters, click on OK. 

System Response: The Define Shipcase dialog box closes. The 

Select Shipcase dialog box re-appears with the parameters for the new 

tray. 

5. From the Select Shipcase dialog box, click on OK. 

System Response: MixPro saves the new tray to the database. 

(MixPro saves the tray as a shipcase.) The MixPro Tray Editor reappears, 

as pictured below, with the new tray name (ArmorAll) 

displayed next to the Shipcase button. 


Step 2: Create New Packages. 

Look at the package list and decide which items you want to place onto 

the tray. In this exercise, we want the mixed tray to include ArmorAll 

spray bottles and cloth packets. Notice that the initial package list does 

not include any of these items. In this case, MixPro allows you to create 

new packages for these items. Follow these instructions: 

1. From the MixPro Tray Editor, click on the New button. 

System Response: The Define Package Info dialog box appears, as 


2. Use the following fields to define the ArmorAll spray bottle: 

Style: Use the drop-down box to select a tray template (in this 

exercise, hairsp.tpr). 

Name: Enter ArmorAll Spray. 





If you want, you can also define a label for each package and assign 

the case a specific color. 

3. After completing the package dimensions, click on OK. 

System Response: MixPro saves the new package to the database. 

The MixPro Tray Editor re-appears with the name of the new package 

included in the package list. 

4. Repeat steps 2 and 3 to create the ArmorAll Cloth Packets. Use these 

dimensions: 

Style: Use the drop-down box to select a tray template (in this 

exercise, 2alarm1.tpr). 

Name: Enter ArmorAll Cloth. 




Step 3: Add the Packages to the Pick List. 

In order to place a package onto the tray, you have to move it from the 

package list to the pick list. To move an item to the pick list, follow these 

instructions: 

1. Select an item from the package list and click on the Add button. 

System Response: The system inserts the selected item into the pick 

list. A graphic of the selected package appears in the g.o.d. (graphic 

online display) window, located in upper left corner of the data display 

window, as pictured below. 


Note: To change the orientation of the package – for example, position it 

on its side or on its end – click on the face of the package you want to face 

the floor. Click on the top of the package to rotate 90 degrees. 

Step 4: Load the Items onto the Tray. 

1. To load an item onto the tray, click on the image of the item and drag 

it onto the tray. 

System Response: The system copies an image of the item to the tray 

area. 

Repeat this step until the tray contains six ArmorAll spray bottles. 

When you’ve done this, the screen will look similar to the one pictured 

below. 

2. Repeat step 1 to place 12 ArmorAll Cloth Packets onto the tray. When 

you’ve loaded the tray with spray bottles and cloth packets, your tray 

will look similar to the tray pictured below. 


3. If the ArmorAll tray is the way you want it, open the File menu and 

select the Save As option. 

System Response: The Save As dialog box appears, as pictured 

below. 

4. Select a location where the file will be saved. In the File name field, 

enter the name of the mixed tray (ArmorAll). 

5. Click on the Save button. 

System Response: MixPro saves the tray to the database. 

Tips for Working with Packages on a Tray 

To add a second package to the tray, hold down the Shift key and click 

on the first package. To place the second package on top of the first, 

Shift and click on top of the first package. To place the second 

package to the side of the first, Shift and click on the side of the first 

package. 

If you’ve loaded a column, row or layer of packages on the tray, you 

can add another column, row or layer with one click. For example, to 

add a layer of packages, hold down the Shift key and click on the top 

of the first layer. The system adds another layer on top of the first 

layer. To remove a layer of packages, hold down the Alt and Shift 

keys simultaneously and click on the layer. 

To remove (or delete) one or more packages from the tray, click on the 

package(s) and drag it off the backside of the tray (to the left). The 

package(s) completely disappear from the display. 

To temporarily remove one or more packages from the tray – you want 

to load it back later – click on the package(s) and drag it off the front 

side of the tray (to the right). The package(s) remain in view on the 

display. 


Right-click to display a small menu that allows you to position a 

package on the tray in a number of directions. The first menu provides 

the following functions: 

− Hgt Vertical 

− Len Vertical 

− Wid Vertical 

For the height, length and width vertical functions, you have four 

additional functions: 

− Face Forward 

− Face Left 

− Face Back 

− Face Right 

Using these guidelines, continue to load packages until you’ve loaded as 

many spray bottles as you want to the tray. 


TOPSePAC ® 

TOPSePAC ® is a web-based application that allows users to bring package 

design and stacking strength analysis on the road, performing the task 

anytime, anywhere, on any platform using an internet browser. 

In addition to package design portability and assurance that products are 

optimized for shipping, TOPSePAC ® provides the following benefits: 

Lower Total Cost of Ownership: No software to install or maintain. 

Reduces IT support costs and enables you to stay up to date with the 

latest version of TOPSePAC ® . 

Better Data Management: Central location for storing all data with 

no distance or WAN limitations. 

Easier to Manage: Maintain and manage software configurations and 

default data at a single point. 

Value Added Customer Service: Sales reps can perform package 

design and palletization in seconds – all this in front of the customer! 

Easy Sharing of Data: Give customers and other departments viewonly 

access to the data. 

Integration: Analysis and solution data in XML format can be easily 

integrated with your in-house, web-based systems. 

Compatibility: Compatible with all operating systems. 

TOPSePAC ® is an optional add-on available to TOPS ® Pro users with a 

network license and MVP subscription. It is also available independently 

with a minimum number of license purchase. 

To receive more information on TOPSePAC ® or set up a trial account, 

please contact TOPS ® sales team at 972-739-8677 or email us at 

info@topseng.com.

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