Unnecessary empty space is always an issue with packaging, especially when several components are packaged individually. This is also the case at technology company Continental. Smurfit Kappa has now optimised the packaging for its rubber timing belt set.
Continental has developed numerous innovations since it was founded in 1871. From rubber products for horse hooves to the invention of tread tyres for cars in 1904, the company is a driver of innovation for mobility in the areas of vehicles, machines, traffic and transport. The ContiTech division manufactures timing belt drives, among other things.
But ContiTech is not just about the continuous development of its products. The company was looking for a new packaging concept for its timing belt kit with water pump. This is used in the automotive sector: In engines in which the timing belt also drives the water pump, the pump should also be replaced every time the timing belt is changed. The kit includes all the necessary components.
New packaging for many components
To date, all individual parts (timing belt, water pump, two idler pulleys, one tensioning pulley, one replacement sticker and fastening materials) have been delivered in a total of up to five components, which in turn are packed in a larger outer carton. were shipped. The problem: a lot of air was ultimately transported. The challenge for Smurfit Kappa consisted of Smaller, lighter and more sustainable solution to find the right solution. In doing so, the company had to take into account ContiTech's different production requirements.
In order to understand the processes and requirements, Smurfit Kappa analysed the entire supply chain as a first step. With its own SupplySmart analyser, the packaging company can penetrate complex processes on the customer side and, based on this, develop a Customised packaging concept develop the new products on the basis of simulations.
The result for ContiTech consists of an optimised One-piece packaging with integrated inlay, which consists of just two components. A specially folded upper cardboard insert separates the sensitive water pump from the other parts. In the lower part of the double base, the timing belt, two idler pulleys, a tensioning pulley, replacement stickers and fastening materials are separated and protected by an additional four-part fold.
The optimised packaging has a number of advantages. For example, there is less waste in production and the packaging steps have been simplified. ContiTech now saves around 50 per cent material in the cardboard packaging. The compact packaging means that around 70 per cent more kits on a transport pallet. This saves ContiTech 98 truck journeys or 100,000 truck kilometres and therefore 390 tonnes of CO2 per year. In addition, less space is needed on the retailers' shelves, their workplace remains clearer and they have to Dispose of less packaging waste. The solution is characterised by simplified handling combined with a high level of protection.
The co-operation between ContiTech and Smurfit Kappa illustrates the savings potential that results from the reduction of empty volumes. Due to the large savings in material and CO2 Smurfit Kappa was directly commissioned to analyse further packaging sets.
Source: Smurfit Kappa
