The Challenge: Developing a Lightweight yet Protective Packaging Solution
The customer required a completely new packaging design for its heavy, high-value battery packs. To meet internal health and safety limits, the packaging hood had to weigh under 100 pounds. This specific weight limit allowed two workers to manually lift and handle the hood safely.
At the same time, the crate needed to be tough enough to protect the batteries during transit and comply with dangerous goods regulations.
Standard packaging options fell short. Skeleton crates failed dangerous goods compliance for defective batteries, while traditional cleated crates were far too heavy to meet the manual handling requirements. The customer needed a partner who could balance strict weight limits with extreme durability.
Nefab's Solution: Hybrid Steel-and-Plywood Design for Strength and Compliance
We developed a highly engineered ExPak solution made from a hybrid of plywood and steel. This combination delivered the required structural strength without exceeding the strict maximum weight limit. To improve ergonomics, we added heavy-duty webbing handles to the hood, making manual handling much easier and safer for the workers.
During the initial design phase, we worked closely with the customer's teams to enhance the crate's structural integrity based on real-world feedback. We redesigned the solution with a slightly heavier lid while still keeping it safely under the 100-pound limit, and improved the plywood locking features. We also extended the plywood wall around the base to act as a supportive outer boundary.
Because we adapted quickly to these changing needs, the rollout moved fast, meeting the customer's demanding timelines.
