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The Logistic Packaging team knows that standard packaging solutions need a few extra details to solve the customer’s problem. This is why we always start with a detailed discussion and, whenever possible, a visit at the customer’s premises to see the problem. This approach helped us configure customized foldable pallet containers for a tier 2 automotive producer facing negative comments on orders from their main client.
The Problem: Complicated and Unreliable Packaging for Fragile Car Parts
Our client’s largest ongoing project is producing aluminum parts for a major European car brand. These parts are fragile, and their proper functioning is critical for the normal running of the car engine.
Two of the key requirements from the car maker is complete hygiene and protection from mechanical shocks. To meet these requirements, our client used bubble wrap for each individual part..The parts were arranged into cardboard boxes, with wrapping paper layers between them.
At the unloading point, the car maker employees spent a lot of time unwrapping the products, and dealing with the one-way packaging which had to be eliminated.
Despite These Efforts, The Deliveries Still Fell Below Standards
As if this issue was not sufficient, the auto maker continually sent comments stating that they found dust on some of the parts. In some cases, the aluminum parts had signs of mechanical damage and were sent back.
The parts producer feared that, at this rate, they would lose their biggest client. Thus, they decided to enlist the Logistic Packaging team to help them improve their packaging solutions.
The Logistic Packaging Team Identifies More Issues in the Logistics Processes
During our consultant’s visit to the client’s premises, we identified another costly issue. Due to the fact that the cardboard boxes had a reduced mechanical resistance, the pallets were never loaded to full capacity.
This means that the shipping costs were completely unoptimized, because the client had to take up more trailer space than necessary with each order delivery.
All in all, we identified several problems that had to be addressed urgently:
- Improving protection against dust, dirt and contaminants
- Offering products superior mechanical protection against mechanical shocks
- Reducing the quantity of single-use packaging that the end client had to deal with
- Optimizing trailer space for product delivery.
Our Solution: Customized Foldable Pallet Containers with Foam Inserts and Trays
At once, it was clear that we could not solve all these issues with a standard packaging solution. However, the Logistic Packaging experts identified a model of large pallet containers as the starting point for creating a unique packaging unit for the client.
We added several inner trays, each holding aluminum parts firmly nested into die-cut foam inserts. Finally, we added a container lid to protect the packaged products from dust, dirt and other contaminants.
These layers and inserts help:
- Maximize the density of products per container
- Prevent the sensitive products from making contact with one another or being crushed under the weight of upper layers
- Prevent scratches and any other damage caused by mechanical shocks.
Also, the customized foldable pallet containers have a high stacking load. This will help the customer maximize the use of vertical space in the trailer, reducing the total volume (and cost) of their shipment.
Moreover, all the packaging materials are reusable and will be sent back to the parts producer after the products are unloaded. The foldable pallets can reduce their volume by almost 70 when they are empty, making return logistics affordable.
The Client Tests a Small Batch of Customized Foldable Containers
The client ordered a small batch of foldable pallet containers with trays and foam inserts and used them for a product shipment, asking the car maker for detailed feedback on the new packaging solution.
The feedback was more than positive. The warehouse workers had no trouble unpacking the aluminum parts and collapsing the empty containers for the return journey. They did not find any damaged item in the order and every packaged part was perfectly clean.
This feedback encouraged the client to start the full replacement of the old packaging materials with the customized pallet containers. Several months later, they reported a visible decrease in shipping costs, which allowed them to plan some upgrades for their production lines.
Logistic Packaging can help you turn a packaging problem into a success story with our know-how and extensive range of products. Send us an email and let us help you find or design the adequate returnable packaging solution for your business needs!
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