JANUARY 2009

Reducing packaging and palletisation

We were recently asked by a customer to look at ways of reducing the weight of packaging they were using for their range of Tesco Whole Foods packaging and also to improve the packing speed in their production area.

The original design was an E flute die-cut tray with a 0200 style B flute lid. The tray was hand assembled and due to the light weight of the product being packed, it was thought that it was also over specified.

Our initial proposal was for a 4 corner glued 650 micron unbleached solid board tray which eliminated the assembly stage completely and also showed a cost saving and a 22% weight saving over the E flute.

An additional advantage was the 32% improvement in palletisation of the empty packaging which reduces transport and storage costs.

A further saving was possible by changing the lids from B flute to E flute giving a 18% weight saving and a 75% improvement on palletisation. However, due to the height and total weight of the finished pallets this E flute option was deemed to not have enough strength to survive the multiple handling through the distribution network.

We are also looking at hybrid grades that can offer some degree of weight saving and still perform to the necessary standard.

For further information, contact Steve Thompson on 01642 877177