As a second part two our blog series focusing on customer case studies, we will be providing insight into a project we completed for a customer in the kitchen appliance world.
This case study will focus on the level of packaging expertise we provide at BoldtSmith Packaging.
The project goal was to determine the optimized packaging material and design to ship this product into big box retailers such as Home Depot and Lowe’s around the United States and Canada. Our customer guided us to provide a solution that will not only reduce damage but also reduce freight and material costs in parallel.
Upon kicking off the project, we discovered that the current packaging was not currently passing the customers current testing protocol which consisted of ten 30” drops. The importance of an accurate test cannot be under stated and for this reason, we recommended our customer to allow us to ship the product and packaging with our data recording device. This device records all relative hazards such as drop height, drop orientation, vibration frequency, temperature and humidity.
Along with completing visits at all stopping points in the supply chain from the location of manufacturing, 3PL’s, railyards and customer distribution centers, we determined how the product is handled and stored. Merging the data recorder information with our observations in the supply chain, we created a custom testing protocol that matched the hazards the product and packaging should expect to see. This gives us the data to confidentially give our customer recommendations on the optimized packaging designs.
How many packaging designs and material options would you anticipate your current packaging manufacturer would provide? From our experience, a packaging manufacturer will provide a solution with the material they sell. A corrugated supplier will provide a corrugated solution and a foam supplier will provide a foam solution as an example. This is where the advantage of BoldtSmith Packaging comes in!
Since we do not sell, broker or manufacture packaging, our goal is to provide the best possible packaging solution to our customers. For this particular project, we explored any and all packaging materials that were relevant. Within these materials, we provided multiple solutions to survive the custom testing protocol.
The current packaging as shown in the image consisted of #275 C-Flute corrugated with two EPS end caps. Upon testing the current packaging to the custom testing protocol, it failed in nearly all of the testing hazards (drop, stacked vibration, vertical compression).
The optimized packaging solutions we created were designed around cubing out the trailers the product ships in. The product was manufactured out of country and dispersed through a series of distribution center’s domestically in the United States. For this reason, filling the trailers to capacity was a critical variable in reducing costs. The solutions we designed were sampled, tested and then sent out for pricing. This information was put into a financial analysis comparing current to optimized.
The financial analysis comparing current to optimized resulted in a 25% reduction in freight and 46% reduction in packaging material costs. This was all completed while in parallel passing the custom testing protocol.
If your company would be interested in having a team of packaging experts analyze the current packaging, reach out to BoldtSmith Packaging to schedule a call to discuss!