Challenge: Cost, Safety & Shipping Efficiency
As demand for shipping products via air freight increased, the customer found their existing packaging solution was becoming expensive. The weight and bulk of their previous packaging solution drove up air freight expenses. They needed a more cost-effective alternative that did not compromise on protection or handling efficiency. In particular, they needed to ensure robust shock protection for large, heavy equipment during transit. They also wanted to improved the efficency of the packing and unpacking process.
Nefab’s Solution – ExPak XL Solution
A comprehensive packaging solution was developed using the ExPak XL system to address the customer's specific needs for cost reduction, safety, and efficiency. The Nefab ExPak XL is a strong, plywood-based outer packaging solution. It’s an alternative to wooden crates that can be assembled faster and more safely, without the use of nail guns. For large heavy-duty applications: ExPak XL is ideal for companies that need to pack large products weighing several tons.
- Nail-less Design with Integrated Ramp: The innovative nail-less design allows for quick and easy assembly and disassembly without requiring any tools. This simplifies the logistical process for the end customer during unpacking. A ramp was also incorporated into the design, making it easier to load and unload the heavy equipment and maneuver it through narrow spaces.
- Lightweight Materials: The new design achieved a 40% weight reduction compared to the previous solution. This significantly lowered overall shipping costs for air freight while maintaining the durability and protection standards required. The lighter packaging also created a safer handling environment for personnel during loading and unloading.
- Enhanced Shock Protection: Through advanced engineering, the solution was optimized to provide improved shock protection while using fewer materials. Extraneous elements like foam and excess wooden fitments were eliminated, successfully enhancing product safety and minimizing environmental impact.
