Proper packaging simplifies the handling, transporting and storing of goods; but it also protects them from potential damage. Corrugated packaging is one option that can effectively protect products throughout the distribution cycle. It can be designed for strength and efficiency, while also providing cushioning and rigidity to deliver superior protection. Corrugated can also be manufactured specifically for the applications it is intended for including, the most fragile products—glass.
When Protection Isn’t the Only Factor
For a large manufacturer of custom doors and windows, corrugated has always been the ideal choice to protect their fragile yet heavy products for transport. Some weigh more than 300 pounds. Corrugated has provided the strength and rigidity they need to handle rigors from over-the-road transit; however, rough handling in the warehouse was compromising the corrugated packaging as it was being moved onto the truck. As a result, the company was facing a number of damage claims annually.
This company’s main corrugated supplier was PCA. When PCA General Manager Neil Turley became aware of the issues the customer was having with damage, he brought in PCA’s Performance Packaging Group (PPG) to further evaluate the company’s current packaging and develop a solution. The new corrugated packaging design had to endure rigorous handling, accommodate the customer’s current truckload capacities, and withstand the demands associated with over-the-road transportation.
Identifying the Solution
PPG began by testing different corrugated designs and coatings. They decided on corrugated with a coating from Michelman, Inc. The coating would help protect the corrugated from moisture, while its smoother finish would simplify handling of this company’s products. Once the PPG determined the type of corrugated to use, they went to work adjusting the design specifically for the application and conditions necessary. By testing and adjusting the perforation and scoring patterns, PPG determined they could wrap the corrugated packaging around the products tighter and without catch points to ensure packaging stayed taut during handling. The revised corrugated construction would withstand rough handling in the warehouse and provide the strength and rigidity to protect the company’s products throughout the transportation cycle. As an added benefit, the new design eliminated any ancillary packaging materials, which resulted in fewer steps to complete the process and led to faster packaging times.
For this company, their corrugated packaging was providing adequate product protection for their transportation conditions but handling in the warehouse was compromising that packaging solution. Through a comprehensive analysis, PCA’s Performance Packaging Group was able to evaluate the company’s products through their manufacturing and distribution touchpoints to develop a solution specifically for their unique needs. As a result, PCA’s complete corrugated solution has helped this customer to significantly reduce their annual claims as well as increase packaging efficiency.
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