XXL size. Innovative use of cardboard in logistics by Smurfit Kappa.

Symbolic evolution of transport packaging.

Safety, ecology and convenience have a key meaning in typical industrial packaging. Owing to the experience of more than 300 factories on three continents and the access to unique design tools Smurfit Kappa is persuading the market that large-size transport packaging is developing as quickly as SRP.

Piotr Pranczke

In many segments of packaging industry issues of  weight, cellulose paper and bursting are repeatedly discussed. Yet, it is strength and safety of the product that are more significant than another printed colour. A few years ago Smurfit Kappa Poland made a decision to specialise in producing large-size packaging commonly called XXL & Heavy Duty in one of their five Polish factories. Owing to adjustment of the plant to this market segment (among others an investment in a new technological line BGM with production capacity of XXL packaging sheets up to 5meters long), Smurfit Kappa Poland has become one of the leaders in XXL sector.

Octabins are reliable, multi-layer cartboard boxes designed to transport very heavy bulk products, deep-frozen or significantly cooled goods.

XXL packaging

XXL & Heavy Duty sectors specialised thanks to, among others, octabins. This type of packaging is dedicated mainly to chemical  and refrigeration industry. The octagonal shape of packaging is the best solution when it is required to transport bulk materials of significant weight or the packed product is deep-frozen or significantly cooled. Due to long storage period of products and often extremely adverse conditions of warehousing, it is necessary to use resistant, 5- or 7-layer cardboard of weight no lower than 1000 g/m². The optimal octabin project is, apart from the strong box itself, appropriate protection that guarantees a safe delivery to the final destination located even a few thousands kilometers away. The quality of roads in some countries is still very questionable. It happens that packaging that has proved to be reliable for many years in Western Europe utterly fails during transport on roads of worse quality. Considering difficult transport conditions Smurfit Kappa, in cooperation with German TUV, formulated , tested and accepted safe transport of octabins. New, patented solution called Easylock is a combination of a special sleeve-type shape made from strong cartonboard resistant to moisture and standard safety belts used by transport companies to secure the load. The advantage of a proposed solution, apart from safety guarantee, is a competitive price in comparison to other standard protection equipment. Other examples of interesting and unique solutions that meet the highest strength requirements are heavy duty packaging Flotainer and Stacktainer (for the heaviest applications), Easytainer (with automatic bottom, easy and convenient to fold by one person), Freezetainer (for deep-frozen products; up to -28 °C), and Viscontainer (for liquids storage).

Cardboard fillers also work for electronics industry as a less expensive alternative to the expanded polystyrene.

Cardboard fillers

Transport packaging includes as well boxes for transporting individual items of larger dimensions such as tv sets, windows, washing machines or components for automotive industry. In such cases packaging is not only a colourful box that can be seen in shops but also internal protection elements. Until recently, expanded polystyrene was commonly used as product protection in bulk packaging. However, recent years have brought significant changes. Increasing customer awareness, fashion for ecological solutions and legislation resulted in cardboard becoming an interesting alternative. Smurfit Kappa has been promoting “full corrugated-type” solutions for many years. Owing to unique design tools – Innotools, as well as using Innobook database, in which one can find the best practices used in more than 300 plants, Smurfit Kappa specialists are able to offer an interesting practical solution for every product.

One of successful examples of using cardboard fillers instead of EPS is a project prepared for a large roof windows manufacturer. Over two years ago the customer enquired whether it is possible to replace styrofoam end caps with cardboard. It was a requirement by one of the recipients, who set some conditions for the future cooperation, among others, all the products were required to be packed in 100% eco-friendly packaging. The task was not easy, considering the fact that the weight of windows happened to exceed 30 kg. Owing to close cooperation between developers on the provider’s side and the customer, a solution was established that would meet strict strength requirements. The “side effect” of this implemented product is logistics savings (cardboard end caps are packed flat) as well as the cost of the entire package. After a few months of market testing, the customer made a decision to introduce the cardboard end cups for all their products.

Cardboard packaging for tyres – Wheelbox – is gaining more and more popularity, since it is an efficient and safe solution.

Tektura na okrągło

Another interesting example of cardboard fillers use are products from electronics and automotive industries. Here, apart from safety and ecology, it is important for the proposed solution to be economical. Cardboard fillers are usually less expensive than expanded polystyrene. An additional advantage is several times lower cost of tools and significantly shorter period of time required to implement the new product. Tyre replacement services use cardboard packaging more and more often in order to avoid any damage during the storage of customer’s goods. Smurfit Kappa offers a special box – Wheelbox – designed for safe storage. The cardboard that has been used here – Powerboard – guarantees a possibility to use the packaging even throughout seven seasons. It may seem that transport packaging made of heavy cardboards is not friendly to the end user. Many consumers, when buying for instance white goods, needed to struggle and use a wallpaper knife to get to their dream fridge. Smurfit Kappa has developed a special packaging construction that facilitates opening of large boxes. A special reinforced paper tape not only joins the packaging sides but can function as well as a breaking tape – so-called “zipper.”

The above examples show that large-size transport packaging is evolving as quickly as SRP. Safety, ecology and convenience have the key importance also in typical industrial packaging. Smurfit Kappa, owing to experience of more than 300 plants on three continents as well as access to unique design tools - Innotools, is able to offer interesting solutions for all kinds of industries.

www.smurfitkappa.pl