Logistics service provider Duvenbeck was faced with the problem that the packaging it was using for heavy components from an automotive supplier during overseas transport did not meet the stability criteria or the necessary corrosion protection requirements. Experts were needed to develop customised, optimally adapted solutions.
Sometimes standard packaging is just not enough: the problem was that components weighing around 25 kilograms were arranged upright in the inner packaging and only held in position by the walls of the compartment. These could not withstand the dynamic forces that typically occur during transport, and the packaging collapsed. And despite the corrosion protection used, the components corroded. Both led to costly complaints.
Packaging processes as well as storage and transport conditions require customised solutions that enable Optimise packaging along the entire process chain. The development of stable overseas packaging with integrated corrosion protection, which also improves storage logistics and container utilisation, requires appropriate Expertise from specialists in demand.
After thoroughly analysing all relevant parts of the process, we develop an economical and efficient solution that is specific to the packaged goods. Teams of experts from Billet, the packaging wholesaler from Hann. Münden. One requirement was to provide special protection for certain parts of the assembly and not to expose them to pressure loads. In contrast to the previous packaging, the components are packed horizontally and Recesses in the base plate fixed in such a way that they remain in position during transport, do not press into the compartments inside the packaging and therefore cannot jeopardise the stability of the packaging. Thanks to additional perforations in the base plate, the recesses are variable in size, and different component variants can be accommodated, which reduces the overall number of packaging variants.
The packaging is labelled Poka-yoke principle designed: The foresighted avoidance of errors contributes to process reliability, and the clear defined processes also reduce packing times. A plus point on top: a wooden reinforcement has been integrated so that the crates can be stacked despite their high weight.
The components corroded in the original packaging. Knüppel has therefore optimised the corrosion protection concept: For their solution, the packaging experts use VCI bag which are fixed in the compartments and therefore cannot come loose and open. The VCI active ingredient remains in the packaging and reliably protects the components from corrosion. „Our Customer has demonstrably reduced the complaint rate with our packaging solution“, summarises Florian Resmerowski, Product Manager at Knüppel Packaging Development.
Especially for Overseas packaging plays a major role for world export champion Germany. According to the Federal Statistical Office, motor vehicles and motor vehicle parts accounted for 15.6 per cent of German exports in 2020, followed by 14.6 per cent for machinery. Both sectors contain a large proportion of corrosion-sensitive components that need to be protected against corrosion during long journeys with climatic fluctuations. This is also the case with the axle components that Knüppel customer Duvenbeck transports overseas for an automotive supplier.
The solution was developed in Cooperation with the partner Excor Corrosion protection technologies and products, which has been a leading supplier on the market for volatile corrosion inhibitors (VCI) for 30 years.
The packaging is delivered flat, as a set and compactly folded. Thus it saves space in the warehouse and in intralogistics. The size of the outer packaging is designed in such a way that the selected sea container can be loaded in a form-fitting manner, taking into account the best utilisation of space. The The basic concept of this transport packaging is therefore suitable for different industries. A manufacturer of automotive exteriors is currently also using it in an adapted form to transport its components to China.
With the Development of new and customised packaging there is a Holistic approach at the centreFrom the on-site analysis, in which all relevant criteria such as quantity, type of transport, disposable or reusable packaging are recorded, to CAD designs, a material concept and costing, through to the creation of a prototype, packaging testing and selection of suitable partners for subsequent series production everything is in one hand.
Whether for series or alternative packaging, solutions specifically for export or packaging concepts for individual objects, we can draw on a very wide range of different materials and packaging materials and designs customised packaging solutions that are precisely tailored to the customer's needs.
Honeycomb board, corrugated cardboard trays, corrugated cardboard transport containers, pallets and VCI film are used for the new overseas packaging. Additional twin-wall sheets, foam and ESD protection are required for returnable packaging.
Throughout the entire development process, the company always has the respective Focus on customer goalsThe aim is to save material and disposal costs, minimise volume, optimise packing density, reduce the number of variants, optimise the packaging process, reduce the complaint rate and simplify warehouse logistics. And that always with the aim of developing packaging that is as sustainable as possible.
