Mastering Packaging Performance and Supply Chain Distribution

Fundamentals of Packaging and Distribution

The relationship between product resistance and packaging protection defines the environmental hazard encountered during transport:

• Product Resistance + Packaging Protection = Environmental Hazard

Defining Protection Levels

Severity is the measure of the environment, while the Product represents the level of resistance it offers.

• Underpackaging: Provides less protective capacity than required.
• Overpackaging: The package protection is higher than necessary, potentially increasing costs.

Six Core Functions of Packaging

The main purpose of packaging is protection during transport and handling.

1. Protection: Shielding against possible hazards such as vibration and shock.
2. Containment: Preventing issues like liquids leaking or humidity affecting electronics.
3. Apportionment: Allowing the product to be modular for easy breakdown or sale.
4. Unitization: Keeping multiple items together for efficient handling.
5. Communication: Providing necessary information via labeling.
6. Convenience: Ensuring ease of use for the consumer, including features like handholds.

Historical Evolution of Packaging Materials

Historically, wood was heavily used and is still utilized today, often in the form of wooden barrels and wooden boxes.

Key Milestones in Packaging History

• Rule 41: This regulation historically discriminated against corrugated cases by placing a 400% tax on them.
• Once corrugated packaging became popular, the Box Certificate was created to standardize quality.
• A significant transition occurred around World War II, moving from wood crates to corrugated boxes.
• Load stabilization was challenging before the widespread use of stretch wrap.
• The emergence of plastics and foams in the 1960s allowed for significant light weighting of packages.

The TEU (Twenty-foot Equivalent Unit) is the standard measure for container capacity.

Packaging Performance and Assessment

Effective packaging performance requires defining three key areas:

1. Define the Product: Determine the limits and handling capacity the product can withstand.
2. Define the Environment: Identify what hazards the product will be exposed to.
3. Investigate Materials: Determine what materials are available and suitable.

Distribution Hazards

Products are exposed to various hazards throughout the supply chain:

• Vibration
• Shock
• Temperature fluctuations
• Compression
• Pressure changes
• Pilferage

Stakeholder Perspectives

A stakeholder is anyone with an investment in a company that could affect the outcome of the distribution process. Stakeholders can be categorized by their position in the supply chain:

• Vertical: How one manufacturer can make the process easier for the next.
• Internal: Focusing on universal pallet sizes to save time within the organization.
• Backward: Relating back to the raw material manufacturer.
• Forward: Relating to the end use of the consumer.

Distribution and Handling Best Practices

Transport costs are significant, often running 3 to 10 times the cost of the packaging itself. Careful planning is essential.

Loading and Container Rules

• Never overload a container based on size or weight limits.
• Consider climate changes and utilize temperature-controlled containers when necessary.
• Always keep the center of gravity as low as possible.
• Place heavy items on the bottom and lighter items on top.
• Place heavy items in the middle of the load for stability.
• Liquids should be placed on the bottom, and dry products on top.

Dunnage is used specifically to prevent movement of items inside the container.

Key Considerations for Packaging Design

Design must balance several factors:

• The product itself (dimensions, weight).
• Fragility or robustness of the item.
• The distribution environment.
• The needs of the end user.

Supply Chain Analysis and Optimization

Product Research Components

Thorough product research involves gathering:

• Qualitative measures and usage data.
• Target audience and competitor analysis.
• Technical, environmental, and legal information.

Assessment and Data Logging

Supply chain assessment involves mapping the process, figuring out what is occurring, and using data loggers to collect empirical evidence. Analyzing this data allows for better decisions, especially regarding cost optimization.

Vibration and Cross-Docking

Vibration is present on every mode of transportation, typically exhibiting a spectrum change between 3 and 30 Hz in amplitude.

Cross-docking involves mixtures of FTL (Full Truckload), LTL (Less than Truckload), and small parcel shipments. Goods are unloaded from one truck and immediately loaded onto another to continue to their final destination, minimizing storage time.