Simple design makes savings
October 1st 2005

A major producer of a high value base product, essential in 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 contaminatefree pack, an end user in Japan was also experiencing cost and environmental difficulties in its disposal. Tri- Wall KK, Japan, was consulted and they requested the Tri-Wall design team at DS Smith’s heavy duty corrugated plant, Monmouth, design a woodfree solution.

The solution combines the proven EcoPal heavy duty paper pallet with a flapped container - all wood has been 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. By using ‘A’ flute corrugated’s inherent cushioning, an inner unstitched sleeve replaces foam inserts.

Another benefit is the increased stacking strength, allowing the packs weighing in excess of 300kg to be stacked three high in storage and two high in shipments.

The simplicity of the new system is reported to have lead to dramatic savings for the manufacturer.

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