Packaging technologists have been great innovators in helping their customers to cut packaging waste, improve product protection and their customers’ green credentials but are packaging users coming up short in their own reappraisals of how packaging/storage affects line-side efficiency, especially when considering a move to JIT? These innovations range from on-site box-making machines to tailor the box size to the contained product to save on packaging materials and freight charges to shrink film using micro-layered technology that uses much less plastic, developed by Sealed Air. In between are the reusable, environmentally-driven innovations like the Re-Usa wraps for pallet loads, an alternative to the high expense and mess of stretch film. Generally used in closed loop distribution channels, they comprise vinyl-coated mesh and Velcro type hook and are 10 times stronger than stretch film, leading to less product damage while in transit. The ROI is typically six months to one year.
It is not difficult to see why packaging users may be short changing themselves over reappraisals owing to the complexity of the interaction between packaging and materials handling techniques in the global supply chain. Matters could be eased, however, by engaging an independent supply chain consultancy with a knowledge of multi-channel distribution. It is not enough for packaging users to consider their own internal packaging use techniques. They must also consider the impact that their packaging might have on their business to business customers because to some extent they could be transferring the problem of handling waste disposal to their customers, perhaps forcing them to invest in balers and compacters or otherwise have to pay for collection of their waste packaging.
To avoid this ‘buck passing’, packaging users should consult their suppliers on not just recyclability, so that they meet the EU’s recycling targets of 75% of packaging waste to be recycled by 2030, but also resourcefulness at eliminating some forms of packaging entirely. The latter has yielded significant gains with lineside deliveries to JIT-geared manufacturers or food retailers. This has been achieved by a combination of one-touch, specially-designed, reusable packaging in the car industry to roll containers fitted with slots to carry plastic food trays for direct delivery to shop shelves. This not only eliminates forklift tasks, pallets and cardboard containers but gives much faster delivery vehicle discharge in a safer manner.
The problem of packaging becomes more complex if thinking of a move to automated warehouses because the former heavily influences the design process for automation and so any planning exercise should begin with an appraisal of stored materials regarding their size, weight, method of load restraint, pallet, tote and tray variations. Trying to force some kind of uniformity of packaging from suppliers would be helpful but very hard to achieve, especially by SMEs. Compared with manual handling, warehouse automation requires better quality packaging and pallets, more consistency and more care over palletising and labelling. Probably the biggest curse is timber pallet inconsistency, even from the same supplier because the quality of dimensional accuracy is paramount. To sidestep the wood pallet problem, some automated warehouse operators use more dimensionally consistent plastic pallets. Conveyors also need careful attention. Belt conveyors pose fewer problems than roller for sub pallet loads, like shrink or stretchwrapped cartons and trays. This would cut down on any snagging problems with loose stretchwrap or banding and prevent incorrect signals to sensors.
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