With less handling, less cost and less waste
An automotive OEM was shipping battery modules for its popular car models from Germany to the US, but the one-way packaging it was using was expensive, difficult to ship safely and created waste. Moreover, it couldn’t be used in their automated production lines, which also meant additional handling, repacking and increased risk.
CHEP was asked to explore a better reusable packaging solution. Battery modules were already supplied inside UN-certified Dangerous Goods housing, so there was no need for a certified transport container. However, the existing triple-walled cardboard external packaging didn’t pack well into sea containers and the internal dunnage dividers degraded easily because of humidity at sea.
Back to the design board
CHEP 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. CHEP packaging engineers went to the container manufacturer to see how the pallet foot tools could be redesigned to solve this problem. This led to a new generation IcoQube 2 container. Allowing for easier handling, it also helped increase weight utilization by up to 95%, thus improving efficiency and reducing costs. Additionally, CHEP’s stronger returnable and foldable containers eliminate the need to dispose of large amounts of cardboard waste.
Building on success
The achievement led CHEP and the same OEM to explore how outer and inner packaging could be combined in a one-stop sustainable solution. CHEP’s Customer Solutions Team used battery module design data to create first concepts for reusable, durable and nestable inserts. Working with a trusted insert supplier, these were then developed and tested using 3D printed samples and a final design was approved for production. The result fully aligns with the OEM's automated lift-assist processes, is resistant to humidity and easily stackable for optimised return shipments.
The new inserts facilitate operational efficiencies that can reduce loading times by 75% compared to one-way packaging.