Source reduced shippers in the face of UPS requirements
- Filed in:
- Protective packaging,
- Source reduction,
- Non-food
Wrager
We, like all companies, have been focused on eliminating waste and excess packaging, especially our corrugated boxes. Recently, the big retailers (same ones pushing source reduction) have mandated that loads under roughly 250 lbs., must be shipped UPS.
Non of our protective packaging was designed for this, much less ISTA 3A. How have other CPG companies met these diametrically opposed requirements?
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Package Design for UPS shipments
Charles Weinberg
Package design to meet the demands of UPS (or any other non palletized load shipping) is a great challenge. The requirements of the package design are dramatically different than standard package design, since the package will see top load, side load, be turned upside down, be thrown around, shipped by air and land, etc.
At MSI, we ship thousands of cases every week via UPS. We provide packaging and fulfillment services and have great case studies of cases designed to meet UPS requirements which are more rigorous than standard case design. Even when the cases meet UPS requirements, damages will be encountered. One case we designed was ship tested and performed fine in initial shipments. When the product line was launched numerous damage claims began to occur. The outer case design was fine, but inner case modifications to prevent product shifting and upside down case drop failures had to be undertaken to prevent damage.
When upgrading packaging, ship tests and drop tests must be done up front. If this step is skipped, problems will be encountered with product damage. Cases must be much more robust and standard stacking strength approaches do not work for UPS shipping. It is almost impossible to create the handling conditions in a lab that will be seen in true shipment. Iterative improvement steps will be the norm and damages must be closely monitored and quickly resolved.
Working in partnership with the shipping service is also a critical step. Packaging suppliers such as FP films, who make biodegradable pillow packs, is also a great approach. Many vendors have package testing labs and will gladly work with you to test packages and make recommendations on package design.
In a nutshell, do not short circuit the design and testing process for any case that will be shipped via UPS or any other individual package service.
Box in a box
psmart
At Pack-Smart we have been seeing growth in requirements for reduced packaging while increasing structural strength for shipping purposes.
Pack-Smart Inc. has developed a technology that reinforces sections of cartons only in areas where reinforcement is required. It works well in applications of powdered goods bottles, and other heavy products. Often it eliminates the need for master cases.
Re-usable, reduced packaging option
Sean Slavin Account Executive Dordan Mfg. Co. Inc
Hello Wrager,
What we propose is that we create for you a custom thermoformed inner pack that is product specific. This inner pack will suspend your product and absorb any impact by acting as an internal spring. This allows you to eliminate almost all of the internal corrugated material and reduce the amount of corrugated used on the outer or master carton. Additionally, these pieces are made from recycled HDPE, nest together on a pallet when not in use, and can be sent back to your company for re-use by the end customer i.e. Wal-Mart, Costco, etc. You may contact me directly if you would like at sslavin@dordan.com.
Thank you.
Source reduced shippers in the face of UPS requirements
Thomas Oris
First and foremost, you must ship your product from point A to point B so that your product arrives properly. With that in mind, how do you provide the most "efficient" package? First, you need to define your goal a bit more specifically.
For example, an earlier comment suggested the use of a custom thermoform inner pack. This would solve your solution, but is this the sustainable way to go? My point is, there is no one sustainable solution. This would help keep your product intact, but as a result you will have a thermoform tray that will be placed in a landfill upon reaching its destination. Additionally, be careful of the term "recycled material." Obtain more information, such as whether it is post industrial or post consumer material. What percentage of both/either.
Reinforcing specific areas of your case may also be a viable solution. However, this could add labor if done manually, and what material is used?
One option, which may sound counter-sustainable, is to do the corrugated testing as mentioned in the first comment to your post, and perhaps use MORE corrugated to meet the rigors of UPS. YES, I SAID MORE CORRUGATED. YES, this is MORE material. However, this material can all be collected and recycled, and used again for another purpose. No material ends up in a landfill. However, even with this, you could see an increase in packaging weight, thus a negative impact on CO2 emissions.
As you can see, there is no clear, obvious choice. Discuss with your team, and your customers and develop a long term strategy that meets those needs.
Reduced Shippers
Barry Machin
We at Savoye Inc are a new European Company just establishing ourselves in the USA.
We have vast experience in protecting goods in transit using our PAC 600 case system (over 500 systems installed).
This sytem removes the need for airbags or peanuts by securing the product in place with shrink film which is auto inserted during carton erection.
The closing of the system can be via our Jivaro machine which automaticlly reduces and closes the case to its fill point so that you only ship the volume of the actual product not expensive void.
Take a look at www.savoyepack.com
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