Case Studies
Packaging Solutions and Services
Case Studies
Leading Aluminum Die Cast Producer
Rapid Development:
Developed new packaging within a week to meet evolving needs.
Penalty Prevention:
Implemented measures to avoid component mixing and associated penalties.
Seaworthy Compliance:
Ensured all packaging met stringent seaworthy standards.
Cost Efficiency:
Addressed overspending through efficient packaging solutions.
Comprehensive Solution:
Managed material, machinery, manpower, and container lashing.
Operational Scale:
Operates 40 packing lines across multiple locations, running 24/7.
High Volume Output:
Packs 2500-3000 pallets monthly with a diverse BOM.
Efficient Manpower:
Employs 50 packers for online packaging, maintaining zero unpacked inventory.
Continuous Improvement:
Implemented work instructions, daily MIS, and safety stock management.
Challenge:
XPERTPACK, a leading provider of packaging solutions, aimed to ensure the safe transport of metal products, particularly for clients in the automotive and components industries, facing longer shipping times over sea routes. Preventing corrosion caused by moisture and avoiding costly degreasing and oil removal processes were key challenges.
Solution:
Outcome:
XPERTPACK offers a patented “Easyload” system that efficiently streamlines material handling, making container loading seamless.
Eliminate Forklifts
Our clients have eliminated forklifts and have been able to drastically reduce other material handling equipments.
Safe Operation
The equipment is non-polluting and poses no safety or health risks for operators
Eliminate Open-Top Containers
Using EasyLoad and efficient packaging, we have helped our clients replace 9000 open-top containers with dry containers that are cheaper and easily available
Efficient Dock Management
Efficient Dock Management by reducing the truck time spent per dock.
Optimized Packaging Solutions for Energy Sector Components
Parts Types: The range includes electrical bus ducts, electrical modules, circuit breakers, and heavy engineering electrical components.
Challenges Faced During Packaging: Among the primary challenges are the vibration sensitivity of parts, handling issues due to large sizes, the complex shapes of each part, and the need to optimize packaging sizes for sea transport.
Packaging Solutions and Materials Used: To meet these challenges, the packaging solutions incorporate a multi-layered approach:
- Segregation for Container Efficiency: Ensuring efficient use of container space to maximize load capacity.
- Comprehensive Inner Packing: Providing robust protection for each component, regardless of its shape or size.
- Moisture and Rust Protection: Utilizing materials and methods that protect against moisture and rust.
- Seaworthy Confidence: Ensuring all packaging materials and methods are suitable for the rigors of sea transport.
- Moisture Absorption Assurance: Using vacuum bags and desiccants to absorb moisture and protect components from environmental damage.
Reduction in Packaging Cost for a Gear Pinion Manufacturer
The client, a large industrial group engaged in the manufacturing of forged gears and pinions, was facing issues with parts getting damaged due to rubbing in transit.
Problem: Heavy & Costly Packaging
The client’s existing wooden packaging solution was costly and added excess weight.
XPERTPACK Solution
Heavy Duty Triple Wall Board: Replaced the wooden box, with corrugation, reducing the packaging weight and cutting costs by 30% from the existing packaging. The new design allowed a stacking strength of 1+1 with 800 kg per pallet load.
Vacuum Thermoformed Trays
Developed to eliminate moisture inside, provide better stability of inner packing, and eliminate damages to parts.
Results
Significant reduction in packaging weight and cost and enhanced product safety during transit.
Vacuum Thermoformed Trays, Automotive & Components, Corrugated Packaging, Design, Prototyping & Testing
XPERTPACK Solution
Heavy Duty Triple Wall Board:
Replaced the wooden box, with corrugation, reducing the packaging weight and cutting costs by 30% from the existing packaging. The new design allowed a stacking strength of 1+1 with 800 kg per pallet load.
Vacuum Thermoformed Trays: Developed to eliminate moisture inside, provide better stability of inner packing, and eliminate damages to parts.
Solution
- Implemented comprehensive packaging strategy tailored to specific requirements.
- Customized packaging solutions developed for each furniture piece, considering size, weight, and vulnerability to damage.
- Utilized special cushioning materials such as foam inserts and corner protectors to provide maximum protection during transit.
- Innovative packaging designs implemented to optimize space utilization and reduce shipping costs without compromising safety.
- Rigorous testing conducted to simulate various transport conditions and identify vulnerabiliti
Scale
- Implementation of packaging solutions resulted in significant improvements in shipping operations.
- Cost-effective packaging strategies maintained competitive pricing without compromising quality
Packaging Solutions for Industrial Parts
Part Types
The range includes automatic conveyors, turntable and conveying systems, case erectors, case makers, delta robots, and gantry robot solutions.
Challenges Faced During Packaging
Among the primary challenges are the irregular shapes of each part, the critical requirement for anti-corrosion and rust-free protection, ensuring moisture-free conditions, optimizing packaging sizes for efficient sea transport, and guaranteeing safe loading and unloading at ports.
Packaging Solutions and Materials Used
To meet these challenges, the packaging solutions incorporate a multi-layered approach:
- Base Pallet Design: Utilizing heat-treated pine wood compliant with ISPM 313 standards to ensure robust support and compliance with international shipping regulations.
- Inner Box Protection: Employing vacuum bags to shield parts from moisture and rust during transit.
- Moisture Management: Introducing desiccants within packaging to absorb any humidity, thereby preserving the integrity of the parts.
- Additional Protection: Inner packing materials such as bubble wrap, EPE foam, and stretch film further safeguard the parts from potential impact during handling and transport.
- Seaworthy Packaging: Ensuring all packaging materials and methods are tailored to withstand the rigors of sea transport, enhancing durability and reliability.
Conclusions
In conclusion, by adopting these comprehensive packaging strategies, the case study underscores significant benefits:
- Corrosion Prevention: Effective packaging solutions effectively shield metal products from corrosion during prolonged shipment durations.
- Enhanced Quality Assurance: The implementation of VCI Seaworthy Packaging ensures products arrive at their destination in optimal condition, thereby elevating overall product quality.
- Risk Mitigation: These measures substantially reduce the likelihood of product defects and damages throughout the supply chain.
Contact XPERTPACK
Discover how Xpertpack can enhance your product packaging with our customized solutions. Contact us today to learn more about our services and how we can assist you in achieving optimal packaging performance.
