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The Tri-Wall
design team at DS Smith’s heavy duty corrugated
plant, Monmouth, has triumphed again. In addition
to solving a costly transit problem for the Haut-Couture
Industry they have also won a 2004 StarPack Award,
in the prestigious Institute of Packaging Competition. |
| Clothing
manufacturers of high quality garments were using
suspension-packaging systems to ship their products
worldwide. The garments were hung vertically from
bars in boxes similar to those used in the removal
industry. Generally full trailer and container shipments
were made; but as packs could only be stacked one
high, any creasing or product damage through collapsing
containers was not tolerated, the cost-to-ship per
item was high. |
| With
the use of high performance corrugated material
the Tri-Wall design team resolved the costly issue
by making full use of the space available in shipping
containers. The replacement packs were designed
to accept product in the horizontal. The trays are
made up forming box sections at both ends and sides
to give maximum strength and stability to the structure.
A central slot is available at each end of the box
to accept the hook of the garment hangers. By alternate-end
flat filling the trays with garments, they hold
themselves in place without damage or creasing,
in storage and transit. The self-locking cap completes
the pack and presents a flat surface for safe multiple
stacking. |
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By replacing the
suspension method of filling it was found that the garments
found their own natural position and that product fill was much
improved without detriment to the garments. Equally by packing
containers in the flat, at table height, it was found to be
easier, faster and caused less lumbar problems with the packers.
The packs could then be multi-stacked for storage and loaded
into containers up to fifteen high for maximum fill. |
| The benefits gained by the manufacturers
in both handling and storage have also been noted by their customers.
Their need to iron and remove creases from the garments has
been fully eliminated whilst the cost-to-ship has reduced by
over 50%. The replacement pack has also proved to be less vulnerable
to theft as the product is less recognisable as high quality
garments, and is more robust giving better protection against
humidity in sea and air shipments. |
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