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Optimised packaging saves every 4th truck of packaging material

Pelipal and Smurfit Kappa have developed packaging with optimised cardboard packaging material that saves material.

Bathroom furniture manufacturer Pelipal was looking for an optimised cardboard packaging material for the packaging of its products. Together with Smurfit Kappa, a solution was developed that is processed on the existing continuous packaging machine and saves every 4th lorry of packaging material. 

The success story of the Pelipal Group began in 1906 with the founding of a joinery and furniture workshop. For the factory in Eisenberg, where the take-away furniture is manufactured, the Need for an optimised packaging solution. Ulrich Henning, Managing Director of Production, has worked closely with the company to achieve this. Smurfit Kappa which designed the first continuous packaging machine for Pelipal around 15 years ago.

„Smurfit Kappa has worked with us to further develop and consistently optimise the packaging. Whereas we initially needed a storage area of 900m² for over 500 different cardboard boxes and blanks, today we only need 300m² of storage space for the packaging machine.

Ulrich Henning

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In order to meet the updated product portfolio of Pelipal in Eisenberg as well as the need for a high cycle times with maximum flexibility in terms of packaging shapes and sizes Smurfit Kappa developed a solution based on two components. The existing cardboard cutting machine has the prerequisites to process the zigzag folded endless corrugated cardboard recommended by Smurfit Kappa and supplied on a pallet.

This works for product cartons of different formats and sizes in both small and larger units. The changeover time to a different size is just a few minutes. The low Waste produced during the automated cutting of the cartons does not have to be disposed of, but can be used as filling and buffer material in the carton to protect the goods. can be used. The solution with continuous corrugated cardboard is significantly cheaper and more flexible than purchasing prefabricated cardboard packaging, which previously often had to be purchased in minimum quantities and also took up more storage space.

Benefits for the environment and customers

Whereas Pelipal used to have to keep over 500 individual cardboard boxes in different formats in stock, these problems have been eliminated by using continuous corrugated cardboard. In addition to the Reduction in material costs, improved packaging purchasing, storage space utilisation and packaging and handling time and enables „just-in-time“ packaging.

The previously used BE profile has been replaced by a significantly lower SE wave profile. The now flatter SE flute significantly reduces the height of the palletised continuous corrugated board and thus increases the quantity per pallet, which of course has a direct effect on the further optimisation of the required storage space and the extension of production runs.

In addition to the reduction in volume, the new SE flute not only has the same physical properties as the BE flute in terms of puncture, burst and edge protection, it also simultaneously improves the stability of the edge protection by a further 5 per cent. Improved restoring forces also improve handling when folding, filling and closing the carton.

The changeover from the BE to the SE wave therefore has an enormous impact on transport. Volume advantage: previously 540lm fitted on one pallet, now it is 700lm. This results in an advantage of almost 30 per cent. For Pelipal, this means a saving of every fourth lorry in the supply of corrugated cardboard. This means that reduced CO2-emissions reduce the burden on the environment, at the same time as process costs are noticeably reduced due to lower warehouse traffic with larger safety stocks.

„We have relied on our collaboration with Smurfit Kappa for over 15 years and are very satisfied with the company's solutions. Smurfit Kappa always provides us with important impulses that can be implemented pragmatically. Even small adjustments to the packaging often have major advantages in terms of efficiency and profitability, which ultimately benefits not only Pelipal and the end customer, but also the environment.

Ulrich Henning

Source: Smurfit Kappa

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