Large, flat electrical items are typically distributed without the protection of a box; strapped to a double wooden pallet while being exposed to the elements. We were approached by a Leicestershire electrical manufacturer and distributor to design a bespoke corrugated solution with the ability to protect fragile products in transit whilst allowing them to stand upright on a single wooden pallet.
The logistics cost of transporting a double pallet was approximately double that of a single pallet when sourced through the customer’s existing haulier so if successful, this project would cut logistics costs in half.
Our in-house design team produced several ideas and prototypes for testing. The customer’s preferred design was a 3-piece box incorporating die cut foam end caps to hold the electrical products in place and create a protective air space between the product and the box.
Throughout the design process, due care and attention was taken to maintain the speed and efficiency of distribution, while ensuring that the process of loading the products into the boxes was straightforward.
Due to the size of the boxes the customer employed our stock and serve solution – where we store packaging in our on-site warehouse facility ready to be called off in smaller quantities on a ‘just in time’ basis. The benefit of this service is the peace of mind that comes with knowing that quantities can be ordered at short notice, while saving valuable space in the customer’s own warehouse facility.
Upon completion of the project, it was estimated that the customer was saving £40,000 per annum on logistics costs by making the switch from transporting double to single pallets – including the cost of the corrugated boxes.
