Global shipping solution utilising semi-chem material

Here we take a look at a project we worked on that was shortlisted for the UK Packaging Awards in the Supply Chain Solution of the Year category, and showcases the global impact our packaging solutions have.

Objectives:

• To create a global shipping solution that would protect product without fail
• To be robust enough to permit three high stacking in containers
• To ensure all materials used were fully recyclable

Design:
The product, a high-performance catering oven that is supplied to cafes and fast-food outlets for warming food, required a robust, sustainable packaging solution to navigate global supply chains through road, sea and air. Supply can be anywhere in the world, but the majority is to distribution hubs in the USA from the manufacturing site in the UK.

To support the launch of an additional oven to the range a new pack was to be created. The brief was to ensure that all elements of the pack were made from corrugated, that material usage was kept to a minimum and that all parts of the product were protected whilst ensuring that minimal ‘fresh air’ was shipped. It was also important that the pack was easy to store and took up little space when waiting to be utilised at the end of the production line.

The pack comprises of fittings to protect the product, an outer sleeve, corrugated pallet, cap, and accessory carton. This allowed all necessary accessories, such as the tools to use the ovens to be packed in a separate box and placed in the pack last of all. This would ensure that the tools, which had previously been placed loosely in the oven, no longer rattled around removing the chance of any damage to either the oven, or the accessories.

A variety of board grades were used to deliver the best performance for each component. These were EB200KT for the outer lid, EB125KT for the accessory carton, BC125KT for the spacers and BC200KKK (150S/C) for the top fitting, outer sleeve and pallet base. The pack weighed in at 12kg when empty, and 62 kg when packed and went through rigorous testing with great success.

Outcome:

Whilst we had designed previous packs for other ranges, initially removing non-recyclable components from the original pack design, this latest design saw us utilise semi-chem board. This was to minimise the potential effect of damp and warm conditions during transit and would prevent the board from delaminating. Whilst this had not been a problem in the past, it was felt that this was a suitable advancement and would also assist in the robustness of the pack when being stacked three high in storage for several months at a time.

We also worked with the team to create a print design that incorporated their branding and logo but also supported the product. The design on the outer sleeve was created by our designer as well as the constructional design of the pack.

The design of this new pack saw our design team engage with the client to develop a new pack, based on a similar design that incorporated several new elements to ensure cost and supply chain efficiencies were maximised. This has been achieved with great success.



Facts and Stats:

• 10,000 + supplied each year and no damages ever reported
• Work undertaken to create brand identity for the client
• Utilisation of semi-chem board to protect against moisture and temperature fluctuation