Explanation to why film-based wrapping is more preferred than corrguated carton material

Film-based wrapping will help to shield the cargoes from moist, water, dirt, damages and toppling during transportation or storage. This will ensure that the cargoes will be safely transported. One example of film-based wrapping is pallet wrap. The pallet wrap film is being wrapped on the cargoes for a few layers. This is done so as to palletize the multiple small packages together in order to have more retention for the load and better resistance in puncture. Since the pallet wrap film is transparent, therefore the labels of the cargoes can be read clearly.

Corrugated carton material is not as preferred as film-based wrapping because of some reasons. Firstly, the cartons may be destroyed when opening it due to difficulty in opening it as it may be enclosed using staples and tapes. This means that the cartons cannot be reused again which is wastage of resources. The cartons of cargoes in film-based wrapping can be easily retrieved by removing the films. Secondly, corrugated carton is unable to contain materials that are having leakage. It will be dangerous if the leakage contains hazardous chemicals. But for film-based wrapping, it will be able to prevent some leakages since the film is waterproof.

Reference:
http://www.maskingfilmshop.com/pallet-wrap-400mm-x-300mts-6-rolls-8-p.asp
http://www.fast-pack.com/stretch-wrap.html
http://www.allround.com.au/pallet_wrap.php
http://www.tapeshoot.com/dispensers.htm

Facilitator’s Question

Under what circumstances film-based wrapping (as shown in your Blog) becomes a preferred choice of logistical packaging instead of corrugated carton material? Explain.

Why must we conduct packaging testing?

Reliability Means Not Just Your Product - it Also Means the Package!

Packaging tests are necessary to be conducted for cargoes that are required to be shipped. Packaging tests are done to lessen the amount of damaged cargoes. They are also done so as to know how well the package can perform.

Other reasons to conduct packaging testing :

• Protect the product (Major reason)


• Save costs (Avoid damaging the product during transportation save money)


• Increase brand loyalty (Customers will lose confidence in the company and brand if a product arrived poor condition)
  
• Get to market faster (Testing reduces the need for trial shipments and allows the new products to market quicker)


• Reduce claim headaches (Establish your package’s adequacy to prevent and defend against claim negotiations)
  

Packaging testing has to be conducted as early in the packaging design stage as possible.

Reference :

http://www.intertek-etlsemko.com/portal/page/cust_portal/ITK_PGR/OUR_SERVICES_PG/PERFORMANCE_BENCHMARK_TESTING_PG/Packaging%20Testing

Different Categories of Packaging Tests

Cargoes that do not have hazard falls under ' General Packaging '.
Some examples of cargoes that use general packaging includes toys, electronics and consumer products. The packaging tests that are required to be performed for general packaging are as follows:

- Humidity, pressure and temperature
- Pre-Conditioning
- Compression test
- Shock test
- Impact test
- Drop test
- Vibration

Cargoes that needs to be sterilize entirely during transportation, handling and storage falls under ' Medical Packaging '.

One example of cargoes that uses medical packaging will include medical instruments. The packaging tests that are required to be performed for medical packaging are as follows:

- Humidity, pressure, temperature

- Pre-Conditioning
- Shock test
- Vaccum test
- Peel, burst, bubble test
- Colour penetration test

Reference:
http://www.tuvps.co.uk/packaging-tests.asp
http://www.halthass.co.nz/reliability/services/pack-test.htm

Basic Facts of Packaging Testing

Packaging protects your product from structural or environmental damage .Whether it is ships in a cardboard box, a crate or a custom-designed case – either domestically or internationally --we need to ensure the packaging meets requirements to avoid damage during transit.

During the process of transporting, storing and even handling, a package is exposed to a variety of stresses during its lifetime. It is vital that the used packaging materials manage these stresses during the whole lifecycle.

Hence, a wide variety of packaging related tests is indeed necessary to ensure that the package is well created and produced. These tests could be performed on paper, paperboard, corrugated board and plastic materials and many other various types of textile. These tests simulate the real stresses to which the materials and packages are exposed in the packaging lifecycle.

At the same time, it ensures the security of the construction and the durability of the materials chosen. Once the packages are tested, it is determined that the packages are ready to face all kinds of possible situations or scenarios happened during the use of it.

Examples of packaging tests and their functions available in the logistical industry are:
· Compression testing – Assess the warehousing stacking and load
· Shock testing – Assess handling, drop and impact
· Vibration testing – Assess transportation vibration
· Sealing test– Assess the optimization of the parameters
· Dropping – Assess the ability to withstand the impact from the drop
· Puncture testing – Assess the durability of the package
· Interlayer adhesion tests –Assess the adhesion between different materials
· Atmosphere testing- Assess the environmental effects (temperature, humidity pressure)

The following videos show how some of the common package testing are conducted.
Enjoy the video!

*Reference to http://www.intertek-etlsemko.com/portal/page/cust_portal/ITK_PGR/OUR_SERVICES_PG/PERFORMANCE_BENCHMARK_TESTING_PG/Packaging%20Testing

Communication Role of Logistical Packaging - RFID Tracking and Packages

An 2005 news article extracted from Information Week , the article was stating that DHL Plans RFID Tags For Every Package It Ships. The goal that DHL had in mind was to gain tighter control of shipments, cut costs, and improve operating performance by reducing paperwork and data collection. One of the reason behind the plan to tag every package it handles is because the transportation and logistics arm of Deutsche Post World Net ships more than a billion packages a year.

Since 1998 onwards, DHL had been testing RFID in 1998 and has since conducted 20 trials with passive and active technology. UPS Inc., by comparison, says it has conducted three big tests, such as using RFID to replace bar codes on packages.

Taken this article as a learning case study, this shows that RFID tracking system is currently an crucial and neccessary idea inputed in the logistical industry. And it will also be a quick emerging trends for most of the logistical packages, especially for products that needed well-protected packages and yet reliable tracking and tracing services to survive in the business for long-term. One of the examples will be the pallet pooling business where tracking is needed very much in the company for collecting back of their pallets.

Reference:
http://www.youtube.com/watch?v=5d_LkbJeWao

http://www.informationweek.com/story/showArticle.jhtml?articleID=164302179

The purposes of packaging and package labels

Packaging and package labelling have several objectives such as Physical Protection, Barrier Protection, Information transmission, Marketing and Convenience

Physical Protection - The objects enclosed in the package may require protection from, among other things, Shock, vibration, compression, temperature, etc.

Barrier Protection - A barrier from oxygen, water vapor, dust, etc., is often required. Some packages contain desiccants or Oxygen absorbers to help extend shelf life.

Information transmission - Packages and labels communicate how to use, transport, recycle, or dispose of the package or product. With pharmaceutical, food, medical, and chemical products, some types of information are requried by governments.

Marketing - The packaging and labels can be used by marketers to encourage potential buyers to purchase the product. Package design has been an important and constantly evolving phenomenon for dozens of years. Marketing Communication and graphic design are applied to the surface of the package and (in many cases) the point of sale display

Convenience - Packages can have features which add convenience in distribution, handling, display, sale, opening, reclosing, use, and reuse.


Reference : http://en.wikipedia.org/wiki/Packaging_and_labelling#Packaging_types

Packaging Types: Cartons

The following are some types of cartons that are being used to package different kinds of cargoes.

1) Pallet Box

Pallet box is a very secure package which helps to store brittle and important cargoes. The two main sizes of pallet boxes are about 110Cm110Cm50Cm and 110Cm110Cm100Cm. There are some choices of the materials being used for the pallet box which includes plastic and cardboard.



Cardboard Pallet Box, Plastic Pallet Box

2) Regular slotted cartons and shipping boxes

These cartons are usually used for shipment and storage purposes, and it requires things like tape and staplers to close the cover. They are very economical and provides protection to the cargoes in it. The materials that are commonly used are paperboard and cardboard.




3) Durable Full Overlap Shipping Cartons

This type of cartons consists of its height that is much shorter than its length and breadth. It has a high resistant to rough usage. The material that is commonly used is cardboard.



Overlap Box

Reference:
http://www.theboxman.com.au/pallet-boxes.html
http://www.buy-plastic-storage.co.uk/product.asp?P_ID=283
http://www.cactuscontainers.com/StandardBoxes/regular-slotted-cartons.html
http://www.cactuscontainers.com/StandardBoxes/full-overlap-boxes.html

Packaging Types - Primary, Secondary and Tertiary

The following piece of search shares with us the various packaging types such as transport package and distribution package.

Packaging Types

Packaging may be looked at as several different types.

Primary packaging is the material that first envelops the product and holds it. This usually is the smallest unit of distribution or use and is the package which is in direct contact with the contents.

Secondary packaging is outside the primary packaging - perhaps used to group primary packages together.

Tertiary packaging is used for bulk handling warehouse storage and transport shipping. The normal form is a unit load that packs tightly into containers.
These broad categories can be somewhat arbitrary. For example, depending on the use, a shrink wrap can be primary packaging when applied directly to the product, secondary packaging when combining smaller packages, and tertiary packaging on some distribution packs

For example, a transport package or distribution package is the package form used to ship store and handle the product or inner packages.

Reference:
http://en.wikipedia.org/wiki/Packaging_and_labelling#Packaging_types

Packaging Types: Poly Bags

A 25-kg Poly Bag is used to contain large amount of powder chemical or dry solid. Some examples of products that are being contained include flours, sugar and fertilizers. The Poly Bag can come in paper bag form or woven form. Woven Poly Bag are more durable than paper Poly Bag as it does not tear easily and when there are rough handling, damages are not made. Woven Poly Bag can be said to be the type of bag that is very frequently used for packing as it is flexible and it can withstand damages.


Poly Bag in Paper Form, Poly Bag in Woven Form

Reference:
http://www.corrpakbps.com/wovenpoly.html
http://www.commerce.com.tw/product/401/Bamboo_Ware_And_Rattan_Ware_Processing_Machine.htm http://buy.ecplaza.net/search/1s1nf20sell/barium_chloride.html

Packaging Types: Drums

Different products will require a specific drum to contain it.

1) Steel Drums
This type of drum is suitable to contain liquids, both hazardous and non-hazardous ones. The size of steel drums is between 5 to 110 gallon drums. The inner and outer sides of the steel drums are usually coated with a layer of paint to prevent rusting and eroding.

2) Plastic Drums
This type of drum is suitable to contain chemicals in both solid and liquid form. For solid chemicals, it can be contained in power or paste form. Examples of liquid chemical include acids and alkaline. Plastic drums are very economical as they can be used many times. Plastic drums are being commonly used as they do not face any damages like rusting and eroding when they are being exposed. In order to prevent any leaking, plastic drums are required to bond a thin plastic film to the inner side.

3) Fiber Drums
This type of drum is suitable for powder chemical products. Fiber drums are made from fiber board or thick paper. Although fiber drums can only be used for a short period of time, but it is more environmentally friendly as it can be recycled easily. Food industry commonly uses fiber drums to contain cargoes that required refrigeration like ice-cream.

Reference:
http://www.steel-plastic-fibre-drums.com/info/steel-plastic-fibre-drums/

Packaging Types : Shrink Wrap Machine.

This video shows how 4x2 cans of COKE are being packed by a shrink wrap machine. It takes only 1 minute to shrink wrap 240 packs.







Reference:
http://www.youtube.com/watch?v=5nL2n6CjEQ4

Package development considerations

Package design and development are often thought of as an integral part of the new product development process. Alternatively, development of a package (or component) can be a separate process, but must be linked closely with the product to be packaged. Package design starts with the identification of all the requirements: structural design, marketing, shelf life, quality assurance, logistics, legal, regulatory, graphic design, end-use, environmental, etc. The design criteria, time targets, resources, and cost constraints need to be established and agreed upon.

Transport packaging needs to be matched to its logistics system. Packages designed for controlled shipments of uniform pallet loads may not be suited to mixed shipments with express carriers.
An example of how package design is affected by other factors is the relationship to logistics. When the distribution system includes individual shipments by a small parcel carrier, the sortation, handling, and mixed stacking make severe demands on the strength and protective ability of the transport package. If the logistics system is for uniform pallet loads that are unitized, the structural design of the package can be designed to those specific needs: vertical stacking, perhaps for a longer time frame. A package designed for one mode of shipment may not be suited for another.

Package design may take place within a company or with various degrees of external packaging engineering. Some sort of formal Project planning and Project Management methodology is required for all but the simplest package design and development programs.

Package development involves considerations for sustainability, environmental responsibiity, and applicable environmental and recycling regulations. It may involve a life cycle assessment which considers the material and energy inputs and outputs to the package, the packaged product (contents), the packaging process, the logistics system, waste management, etc. It is necessary to know the relevant regulatory requirements for point of manufacture, sale, and use.

You may refer to:

http://en.wikipedia.org/wiki/Packaging#Packaging_types

Emerging Trends - Intermediate Bulk Container

Intermediate Bulk Containers



An Intermediate bulk container (IBC) is a container constructed of molded plastic , fiberglass, or plywood with steel reinforcing and is used for storage and transportation of goods.

Recently, Buckhorn has introduce a wide range of Intermediate Bulk Containers (IBCs) for safe, sound and secure liquid material handling. The new IBC advanatges are:

• Molded from FDA-approved materials, USDA-approved designs
  
• Substantially lowers packaging costs and cost per trip with a returnable / reusable system
  
• Limited use of packaging materials (only the liner bag is disposable)
  
• Hygiene - containers do not rot or become corroded, and are easy to clean
  
• Safety - improved product protection and storage
  
• Easy to fill, discharge and transport
  
• Optimal space utilization - stackable and foldable
  
• Secure stacking up to five-high with up to 3,000 lbs. of product*
  
• Withstand temperature extremes
  
• Certified for rail shipping
  
• Tamper-evident features
  
• RFID and other identification options available
  
• Can be filled and shipped with hot liquids

Reference:

http://www.buckhorninc.com/products/intermediate-bulk-containers.asp

Emerging Trends in Logistical Packaging: Plastics Pallets

Pallets are also counted as packaging for products in logistics and warehousing. It usually used as a support base in storage and transporting for many different types of goods in general. Traditionally, pallets are general made with wood, but their usage was riddled with problems like fungus, pests and insects, nails and splinters. Disposal problems of wood pallets are a headache as it carried the threat of land filling/burning etc. This also contributed to the overwhelming concerns arised over the environmental issues. Continuous research has gone into finding the substitutes for wood.


However, Research and Development (R&D) of many logistical packaging companies has comes up with an environmental - friendly, lightweight and recyclable material - Plastics pallets. Plastics pallets has become a upcoming trend in the future logistical packaging field and has been categorised as the 'packaging product of the future'. Although the costs to produce plastics pallets are expensive, benefits are unlimited in the long run.


*Reference to http://www.indiamart.com/ssvpallets/

Emerging Trends in Logistical Packaging: Blanket Wrapping

As we paced into the new century, innovative packaging ideas has to be constantly introduced to maximise the benefits of packaging and minimise the disadvantages.

One of the new effective services - Blanket wrap eliminate crating and other packaging problems and yet increased loading capacity and significant cost savings.

Some advantages known when adopting a blanket wrap service are:

• No disposal costs


• Environmental friendly (Not dependent on paper)


• Minimal floor space needed


• Reduced damage to the product


• Damages noticed immediately ( compared to other packaging where damages could only be noted when unpackaged)


• Increase the number if pieces per load


• Reduced labour costs

*Reference to http://www.elderlitelogistics.com/sol-bktwrap.html

Emerging Trends in Logistical Packaging: Pallet Pools

What is pallet pooling all about?

Renting system - Pallet operator delivers pallets according to orders to the customer. The customer use the pallets to pack and carry their product and transport the product that is securely packaged to their own customers. The customer will then informs the pallet operator when and where pallets have been shipped. The pallet operator arranges to collect the pallets when empty. Once returned to the depot the pallets are inspected and repaired if necessary before starting the cycle again.

Advantages of Pallet Pooling:

• Relatively cheap
• Pallets can be re-used and refurbished many times
• Requires minimal administration
• Reduce number of inventory

Disadvantages of Pallet Pooling:

• Might be prone to theft and unreliable customers
• Difficulties in tracking and tracing

Reference :
http://www.palletlink.co.uk/pallets/pallet-pools/

Practices: Functions of Logistical Packaging

1. To protect a product from damage or contamination by micro-organisms and air, moisture and toxins.
The product must be protected against being dropped, crushed, and the vibration it suffers during transport. Delicate products such as fruits need to be protected by a rigid package such as a laminated container.
The product most also be protected against the climate including high temperatures, humidity, light and gases in the air.
It must also be protected against micro-organisms, chemicals, soil and insects.

2. To keep the product together, to contain it (i.e. So that it does not spill).
Some shapes cannot be easily packaged, for example, certain vegetables. However, there are methods of getting around this problem. Suppliers of canned vegetables such as carrots have developed a particular type of plant that yields carrots that are straight and smaller than the normal variety. These fit into cans. Some products such as fruit juices and sausages need to be contained in packages that hold them together and are sealed to prevent spillage and loss.

3. To identify the product.
Packaging is the main way products are advertised and identified. To the manufacturer the package clearly identifies the product inside and it is usually the package that the customer recognises when shopping.
Advertising is very important when a manufacturer launches a new or existing product. The package, through its colour scheme or logo, is what is normally identified by the customer.
The package will also contain important information including ingredients and ‘sell by date’.

4. Protection during Transport and Ease of Transport.
A package should be designed to make it easy to transport, move and lift. A regular shaped package (such as a cuboid) can be stacked without too much space between each package being wasted. This means that more packages can be transported in a container of a lorry. Unusually shaped packages can lead to space being wasted and this can be costly if thousands of the same package are been transported.

5. Stacking and Storage.
In supermarkets and shops it must be possible to stack packages so that space is not wasted on the shelves. Lost space on shelves is looked up on a lost opportunity to sell to a customer. Also, the package must be designed in such a way that all the important information can be seen by a potential buyer, especially the product name. The next time you visit the supermarket look carefully at the shape of the packages. They are usually the same rectangular / cuboid shape. It is the selection of colours and shades that determine whether the product inside is regarded as a quality, sophisticated or cheap item. Often packages are stacked on top and alongside each other to reduce wasted space. The shape and form of the package determines how efficiently they can be stacked or stored.

Reference:
http://www.technologystudent.com/despro2/packfn1.htm

Practices:Channels used for Packaging

There has been a lot of packaging channels available. Some of the few examples are as stated below:

● Channel used for Sustainable Packaging
This channel concentrates on packaging that can be used for concerns of the environment like plant energy efficiency and organic substances.

● Channel used for Carton, Case Packaging
This channel will consists of materials like cartons, cases, divider, placers and others. This is used for the pharmaceutical and industrial packaging industries.

● Channel used for Filling, Form/Fill/Seal
This channel includes filling, bagging and weighing equipment and pouching and other. This is used in the pharmaceutical and food and beverage industries.

● Channel used for Labeling
This channel includes machines to do labeling, labels and others.

● Channel used for Package Coding
This channel will require marking using laser, chopping, printers and bar coding for the food and beverage and pharmaceutical industries.

● Channel used for Package Handling
This channel is one of the packaging function that consists of equipment used for pallets, containers and others that are used in pharmaceutical and food and beverage industries.

● Channel used for Package Design

● Channel used for Packaging Automation
This channel consists of packaging using robotic equipments, sensors and the integration of system and others.

● Channel used for RFID/Smart Packaging

● Channel used for Rigid Container Packaging
This channel consists of materials such as cans, containers, bottles, packaging made from plastic substance, lid, jar and others. This can be used for the makeup, pharmaceutical and food and beverage industries.

● Channel used for Flexible Packaging
This channel consists of materials such as flexible substances, bags and others.

Reference:
http://www.packagingdigest.com/

Practices: Advice for internal packaging

Internal packaging advice for shipment protection.

From our research, we learnt that it is recommended to leave a space of at least 5cm between the outer container and the product being packed inside.This space serve the purpose to fill it up with cushion such as padding of some type, any substance from crumpled newspaper to old pieces of clothing to prevent vibration or compression.

If any form of damage happens, the cushion will help to reduce the impact. The cushion needs to be able to withstand the pressure caused by compression and can return to its initial form after the cargoes are being loaded and unloaded. The type and amount of cushion to be used depends mainly on the cargo weight and how brittle it is. Brittle cargoes should be packed and wrapped up in an even manner to prevent the cargoes to come in contact with each other which can cause damages.


Cushioning
Different types of cushioning are available, from loose "chips", "shreds" and "peanut" shaped materials to rolls of bubbled-plastic sheet.Loose cushioning is usually made out of very lightweight materials - it's used to fill in corners, keep the articles centred in the container and provide cushioning and shock absorption. It is clean and reusable but can be bulky to store. Most of the fillings available in the market are manufactured from recycled products. Avoid the use of polystyrene, as in many countries it is considered not to be environmentally friendly and it may be forbidden or fined at destination. Vegetable-based and biodegradable materials are preferred.Many materials found around the house can also be used - old newspapers, shredded clothes, cushion stuffing all make ideal cushioning.Bubble wrap is made of pockets of air distributed on a plastic film. It provides very good protection to shock, vibration and abrasion, as well as being lightweight and flexible.

Reference:
http://www.knownet.hhs.gov/log/transDR/LAI/module1/packaging.htm#Basic_Packing_Principles
http://www.dhl.com.sg/publish/sg/en/information/shipping/pack/internal.high.html