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A major
producer of a high value base product, essential
in modern solar panel production, was making bulk
shipments by air to the Far East in a plywood/timber
composite pack with foam inserts. Apart from the
cost involved in a contaminate-free pack, an end
user in Japan was also experiencing both cost and
environmental difficulties in its disposal. Tri-Wall
KK, Japan, was consulted and they in turn requested
the Tri-Wall design team at DS Smith’s heavy
duty corrugated plant, Monmouth, to design a wood
free solution. |
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solution is elegant in its simplicity; by combining
the well-proven EcoPal heavy duty paper pallet with
a flapped container, all wood was removed. The base
flaps are die-cut so that the inner flaps give a
full flat base surface for loading, whilst the short
outer flaps fold back on themselves locking the
pallet in position. The result is a secure palletised
pack that requires no taping or banding. Also by
utilising the inherent cushioning of ‘A’
flute corrugated, an inner unstitched sleeve replaced
the foam inserts. An additional benefit was the
increase in stacking strength, which allowed the
packs weighing in excess of 300kg to be stacked
three high in storage and two high in shipments. |
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The simplicity of
the new system has lead to dramatic savings for the manufacturer,
more than halving the time to pack whilst minimising the storage
requirements for both ‘kd’ packs and storage of
full units. Equally the airfreight costs have been reduced by
nearly 50% and the end user has reported 100% recyclability
with no on-cost. Delighted with the new concept the system has
been introduced on all bulk shipments throughout the world irrespective
of the mode of transport, land, sea or air. And, a new pack
is currently under development for shipping product in 30kg
ingots. |
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EcoPal • EcoPal
Klip • CasePal • PowerPak • TrayPak • Notchfold |
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