Better Box?
- Filed in:
- Boxes,
- Supply chain,
- Optimization,
- Non-food
I am currently working on a "better shoebox" concept that I'd like to gather some feedback on. To date, nearly all shoes are delivered in cardboard boxes. I'm wondering if there is a better way all together.
There are dozens of constraints regarding shoe boxes from how many you can fit into a master carton to stackability to storage footprint at the footwear factory. In all respects, cardboard is cheap, easy to source and conforms easily to addressing many different shapes and sizes. And, it is made from recycled content and recycleable. How much better can we do?
Would anyone have insight as to the environmental impact of switching to a plastic box. Either using sheet material which is die-cut & folded (as cardboard) or molded like a take-out clam shell salad box?
I believe it is possible to design a clam shell which would comply with the constraints listed above. Is there a simple rule for paper vs. plastic? If so, is there a plastic which would be more environmentally responsible?
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good thinking...
Nefabulous
I'm assuming you mean as an inbound flow to the retailer, and not on stock shelves.
If so, plastic is a fit... but then again a high cost is associated to customized returnable plastic containers.
Why not wood? I have customers who use our reuable plywood containers over 500 times. That and the advantage that wood is much more eco-friendly than plastic... and is a much lower investment cost. Don't get me wrong... we sell plastic containers too but there seems to be a fit for each...
Just a thought... keep on brainstorming... we need everyones attention on greener detail.
Carey
sorry
chrish
I was referring to the retail box.
Is there a better way to skin this cat?
cbray
You may want to check out something like our thinWare concept at www.ithinkpak.com. This is a technology we are introducing in several markets right now and had actually discussed shoe boxes once upon a time, but never took it any further.
When it comes to cardboard, it is cheap and easily recycled, but unfortunately like many other products, data would probably show you the consumer is more inclined to toss it in the trash which means laaaaaandfill. That's not good. Like cereal boxes. Statistics show that the average family throws away 8 lbs of cereal packaging every year.
If it was plastic what would happen....Just giving some fodder to think about.
Better shoe box?
Frank Perkowski
Your idea is interesting.
When you say "better" I assume you are speaking in terms of all considerations including environmental impact, functionality, cost, and convenience. From my perspective and without doing a lot of analysis, I believe recycled paperboard is the lowest cost by far and has the least impact on the environment unless you can figure out how to reuse and recycle the plastic or metal alternative. If you can do that and end up using less material overall, then plastic might be viable but only in this case. The other dimensions would probably net out about the same overall between plastic and board with metal being a distant third.
There may be some lower cost and more functional paperboard alternatives such as molded pulp or corrugated that might provide important benefits relative to the existing setup boxes which you may want to consider. Please keep in mind that shoes are largely produced in foreign countries so you need to consider the supply base of materials in those geographic areas. In general, I believe this analysis would also favor paperboard in most cases.
Feel free to contact me if you want to discuss further.
Frank Perkowski
frank@bd-advisory.com
Better shoe box?
Frank Perkowski
one further thought. If you really want to do something innovative and beneficial,you can help implement a shoe box return program with retailers whereby consumers would receive a reward (discount?) for bringing in old boxes. The retailers could then return and recycle these boxes just like the grocery chains do. Everyone would win in this program.
Better Shoe Box
dennis@salazarpackaging.com
I love innovation in packaging but sometimes a package has evolved and and barring any incredibly new technology, has found the ideal design and material solution. The idea of a heartier, reusable shoe box is very desireable and it would undoubtedly make consumers like my wife, very happy. (I am now very well traned and without being asked, automatically turn into any shoe store we come across when we are out shopping.)
I am a big fan of reusable packaging but I find it works best and can be easily cost justified when it can make a full cycle back to the original shipper. Skids, totes and other plastic and wood containers would fall into this category.
I see more show boxes shifting from heavy paperboard to E flute corrugated and I think that is a very positive change but for this application, any paper solution would be tough to beat from a cost and sustainability perspective.
Dennis Salazar
Shoe box
Anonymous...Try using molded fiber. I believe there is a shoebox on sustainabilityisgood.com
that you can see that is made of molded fiber. This is biodegradable and compostable. Much better than plastic
If you are talking about
gangstergunzz...If you are talking about shoes, then Clarks-shoes are best for you. In any size according to your needs and requirement. This is not biodegradable nor compostable, but it is much better than plastic shoes.
I recommend Frogbox
roony2111
According to me the best box would be the FrogBox.Traditional moving supplies are harmful to the environment and time consuming to organize. FrogBox will deliver reusable moving boxes and supplies to your home or office and pick them up when you’re done moving.
better box
sean sabre
Hello Chrish
I think the posts above have covered it and concur that if you stray from recycled bending chipboard with vegetable based inks and aqueous coating (I assume you need a package that conveys branding and some sales text) you are better off with another paper substrate since both molded pulp and thermoform will be cost prohibitive to print on. I guess you could shrink or cello-wrap a pre-printed compostable film over a pulp folding carton (hinged base and lid) to offer a sustainable solution that may be competitive with print on paper but not sure what your volumes are. Do you have access to the Wal-Mart Sustainable Packaging Modeling Tool to perform in-house assessments on your prototyping?
Regards
Sean
Great Feedback
Chris Hillyer...I appreciate all of the guidance here. The footwear industry is really trying to forge ahead with sustainability, yet as I am beginning to realize, we may have happened upon the most sustainable solution years before it was in vogue. From a costing perspective, paper is hard to beat, but as many of you have commented, it may also be the best for the environment.
I am very familiar with 3 seperate attempts for pulp boxes all ending in returning to flute style or high-reclaimed content card. The pulp is miserable in humid conditions, structural integrity as well as poses issues in regards to the lid. Not to mention the cost associated tooling and increased part cost.
I am motivated to find a way to encourage reusability if not recycling since last I checked, 80% of landfills are comprised of paper.
I come from a plastics background and enjoy the concept of lighter-weight, clear packaging which was more water repellant as well as structurally sound. Of course perception is very important here and we all know plastic normally loses out on that front.
I hope I can continue to get some more perspectives on how we can improve. Thanks to all who have participated.
Wal-Mart Packaging Tool
Chris Hillyer...I'd love more information about the Wal-Mart Packaging Tool.
Wal-Mart Packaging Tool
sean sabre
Here is link:
http://www.scorecardmodeling.com/
There are a host of LCA based tools out there and I would encourage you to do your own research but this tool is one of the more user friendly and widely adopted from a retail environment perspective. The Sustainable Packaging Coalition will be releasing COMPASS this month and I would strongly recommend it. The Wal-Mart tool uses a lot of the same LCA data in the background but COMPASS is a bit more comprehensive, strays outside of the vision/mission/strategy confines of the Wal-Mart program and assesses all GHG gasses vs just CO2 via the Wal-Mart tool. Both great tools and if you are going to be working on sustainable packaging initiatives both well worth the money.
Regarding pulp and moisture resistance, a lot of consumer electronics OEMs use this solution and we you know, the majority of electronics contract manufacturing is in Asia so the solution works fine trans-Pacific. Did your moisture testing incorporate any dessicant packs?
Out of the BOX
Dean Bellefleur
Why be restrained by the box? I for one when purchasing a new pair of shoes have for years left the box with the cashier. My justification has been why go to the effort to take it home just to throw it out. This application screams for 2-way-packaging.
Actually your question can be the impetus to a great redesign exercise. Let’s break it down to logistic components starting with the consumer and work backwards. Following the purchase the shoes can be placed in a cloth draw string shoe bag to be taken home. Bring your own or take the vendors branded bag. The shoe bag seconds as a light weight travel bag to be included inside your suitcase.
The vendor then needs a shelving system to inventory the new shoes, no problem. Shoe towers on a dolly platform are wheeled in from the delivery truck to the back of the store. During the delivery the empty shoe tower is removed from the store to be returned to the supplier via the same delivery vehicle.
The shoe manufacturer makes an initial purchase of 2-way-shoe towers to kick-off a “green” initiative that eliminates traditional shoe boxes. Calculate the return on the investment.
There you have it, a feasible solution that I believe you could kick-off an “out of the box” workshop. Bounce this idea around with your creative team and see where it leads.
Shoe box
Scott Dyvig
There have been great comments by all. If recycled content paperboard boxes are a good disposable solution, then the other experts are correct that a reusable system may be the best option for improvement. But I like Dean's suggestion of no take-home packaging. Perhaps shoes be tethered together at the factory, shipped in a plastic-lined reusable gaylord to a regional warehouse, then distributed in reusable tubs to stores where they are displayed and sold. Aside from making dioramas for kids, there aren't many uses for old shoe boxes, I don't think customers will miss them.
Paradigm
chrish
This is where the retail side clashes with the manufacturing side. The writing is on the wall ad eventually we will move towads a "container" which stays at the shop and simply has cards or something to identify what is inside. Why would anyone want to ship cardboard boxes filled with 25% air all the way from China, through a DC and off to stores. Shipping is already expensive.
Many companies making slippers and flip-flop sandals are poly-bag only and save thousands of dollars by filling up containers with product rather than cardboard. Unfortunately, most footwear in the US is purchased by "self-service" displays. These retailers won't even buy flip-flops unless they are shipped in a box! I might add that Wal-Mart is included in this category.
The shift mentioned in the 2 posts above will only happen if retailers embrace the idea that they will be responsible to place product in re-useable bins upon arrival at their DC or retail store. I think it will happen, but it will need to be driven as an environmental initiative, rather than an acceptable solution which reduces packaging.
Better Box?
sean sabre
I like the bag idea myslef but the e-commerce, direct and re-stock qtys of single packs require case packing for parcel transit. Unless the firm in question has the means to re-pack for these channels on demand the bag solution will limit their ability to serve these channels. I think most footwear is brought in direct to distribution with little optimized product configuration and this has supply chain repercussions.
Interesting dialogue.
Better Shoe Box
John Williamson ...Last year I worked with a Canadian group, Pack-Smart. They have a lot of experience in developing specialty cartons and media packaging solutions. I am sure they can come up with something effective.
You should check out their hybridbox.
Good luck, John
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