How a world leading manufacturer increased shipping utilization to 95%

With less handling, less cost, and less waste

The OEM was shipping battery modules for their popular car models from Germany to the US, but the one-way packaging they were using was expensive, difficult to ship safely, and created unsustainable waste. And yet it wasn’t able to be used in their automated production lines, which meant additional handling and repacking – and additional risk. CHEP was asked to see if we could come up with a better reusable packaging solution. Unusually, each of their battery modules was already supplied inside a UN Dangerous Goods certified housing, so there was no need for a DG certified transport container. However, the existing triple-walled cardboard external packaging didn’t pack well in sea containers, and the internal cardboard dunnage dividers could be degraded by humidity at sea.

More utilization by redesign

We started the collaboration process by looking at replacing the exterior packaging. In trials, CHEP’s standard sea shipping IcoQube containers were a challenge for the manufacturer’s hand-operated pump trucks. So our packaging engineers went to our IcoQube manufacturer to see how the pallet foot tools could be redesigned to solve the problem. This led to a new generation IcoQube 2 container that allows easier handling. The IcoQube 2 helped them increase weight utilization by up to 95%, improving efficiency and reducing costs. And using CHEP’s stronger returnable, foldable containers eliminated the need to dispose of large amounts of cardboard waste.

One-stop-shop is better than one-way

This success has led CHEP and the OEM to explore how outer and inner packaging could be combined in a one-stop sustainable solution. CHEP Customer Solutions Team used Computer-Aided Design data for the battery modules to create first concepts for reusable, durable and nestable inserts. Working with the OEM and a trusted insert supplier, these were developed and tested through 3D printed samples to a final design that was signed off for serial production. This is fully aligned with the OEM's automated lift-assist processes, is resistant to humidity, and is easily stackable for optimized return shipments.

The new inserts can lead to operational efficiencies that reduce loading times by 75% compared to one-way packaging.

 

 

5 ways

CHEP are helping one of the world's largest OEMs move more with less

  • Less Waste

    CHEP’s reusable containers and optional inserts are more sustainable than recycling or disposing of one-way packaging. And CHEP’s circular economy model helps them reduce CO2 emissions along their supply chain.

  • More efficiency

    CHEP lets them use standardized containers and customized inserts designed for automation to reduce processing time and increase utilization.

  • Less Cost

    One-way packaging has many hidden costs – more manual labour needed, less utilization, as well as the costs of managing recycling and disposal. CHEP has transparent pricing, with significant savings on shipping, manual labour and packaging management.

  • More Collaboration

    CHEP works with most major automotive OEMs and Tier 1 suppliers across the world. We’ve shared our experience and expertise in transporting  dangerous goods to help them create a better battery transport solution just for their needs.

  • Less Risk

    CHEP is helping them reduce the need for manual handling, eliminating humidity damage and the need for repacking. And with CHEP, the OEM will always have the supply of packaging they need, whatever the demand.

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How a world leading manufacturer increased shipping utilization to 95%