We were approached by a customer manufacturing bedroom furniture who was having a number of issues with product damage on a small pedestal unit, attributed to bad handling by haulier and distribution network. They were seeing a monthly rejection rate of

9% which equated to a cost of over £6,000 in returns for approx. 160 units. In addition to this the cost of admin, return cost, replacement costs amounted to a further £8000 making a total of £14,000 or 18% of sales value.

We conducted on site assessment and monitored transport methods and spent time with the distribution site to Identify where and why the damage was occurring. This highlighted a number of issues. In fact 20% of damage actually occurred in the customers factory, warehouse and despatch. Transport accounted for 18% and the distribution a further 62%.

We trialled a 35 x 35 x 3mm edge protector (Angleboard) which resolved all of the customer and transport issues resulting in 60 units saved from damage. As distribution could be handled several times this proved more difficult but with the edge protection applied reduced damage by 44% saving a further 70 units.

A manufacturer of heavy automotive components had issues with boxes collapsing when double stacking and due to pallets moving the contents were being damaged and some even protruded through the corrugated cases they were packed in. With up to 800kg in each case this would need special consideration.

During initial assessment the heavy boxes were moved several times at the customers plant prior to despatch and the transport journey was usually a few hundred miles. Storage also was a concern as it was often cold and damp.

Out of 140 pallets sent out initially between 5-1 O were rejected, since the introduction of Cornerboard they have had no rejections whatsoever.

A client who was manufacturing high value metal tubes was having problems with damage and subsequent returns.

As a large proportion were exporting this was becoming a real financial issue. After an initial meeting tt was found that approx. 40% of his output was wrapped In corrugated sheets, steel banding was used and then lape was used along lhe length, the other 60% was sent out in paper tubes using plastic end caps again with lape applied along the length.

Although there were 3 common lengths, 3200mm. 5000mm and 6700mm there were often different lengths required which meant the tubes used were no good as when cut they tended to delaminate so this Is where the corrugated wrap was used. They had complained to the haulier about lhe damage being seen but he attributed blame mainly on the movement of the round tubes during transport After on site inspection and transport trial the damage on the tubes was due to their instability being round and the weight of the tubes causing them to rupture at times.

This seemed an ideal application for our transit packaging system "Reddl Crate•. Looking at the size of the tubes and quantities sent out the client would need two sizes: 120 x 160 x 120mm and a larger 210 x 240 x 210mm. Weight was a vital consideration but to save cost we offered a 4.8mm top and 9.6mm bottom to support weight.

Trials were an immediate success and as Reddi Crates are top loaded this saved packing/despatch time over tubes and wrapping.

The square profile meant there was no movement in transport and damage showed a significant reduction. Where shorter lengths of tubes were to be despatched, Redd! Crate can be cut down from standard lengths to suit.

As part of the solution the Reddi Crate tops were printed with customer details and logo making the pack much more professional in its appearance.

One customer who was moving a heavy board product had issues with the transport companies dropping the product on the corner and damaging the profiled edge. They were using a foam protector which although giving good protection in storage where product on shelving was having contact, the weight of the product meant the foam showed no protection qualities when dropped.

We looked at the Issue closely and as 80% + was sent on courier type transport the problem came with handling where often one man would deliver the product. We suggested the use of our "U Profile" in 3mm thickness.

After two months of transit tests the customer switched to the U profile.

Over his annual production not only were his returns reduced by over 70% and the cost of material was reduced by some 45%.

A customer was sending out large volumes of boxed printed material, up to 2,000 pallets per month. To protect the pallets they were using four pieces of edge protection to form a frame around the top boxes on the pallet. They also used four uprights on each of the corners. They had tried self adhesive tape but this was found to damage the printed boxes and so was discounted.

The issue was the time and manpower it took to pack each pallet as they applled the four pieces by taping them together and then inserting the uprights before the pallet was shrinkwrapped.

Each pallet took around five minutes to pack often requiring two packers equating to 330 hours/ £4,125 per month.

After initial familiarisation. the packing time was reduced to under three minutes - a 40% time saving and In monetary terms providing a saving of £39,500.  some 45%.