Surgical products manufacturer DePuy wanted the best of both worlds—outstanding handling ergonomics and low-cost packaging. Finding that new balance wasn't easy, but an innovative returnable container design accomplished both goals. The containers, used to ship surgical instruments and orthopedic devices, have brought DePuy into compliance with a new ergonomics policy of its parent company, Johnson & Johnson. annual shipping costs have also decreased by $275,000.

DePuy had been searching for a new container to replace its former packaging when the ergonomics policy, which limits containers lifted by personnel to 25 pounds, was adopted.

"We used to ship several trays of instruments in one large corrugated container, but it was too heavy to comply with Johnson & Johnson's safety measures," says Doug DeAmaral, DePuy's distribution supervisor.

The company soon realized that any savings achieved from using returnable containers would quickly be lost to increased shipping charges. It costs more to ship several containers under the 25-pound limit than one large carton.

DePuy's solution is new containers that can be strapped together for shipping as a single unit (Flexcon Container, 973-467-3323). The design saves $200,000 a year on outbound shipping costs. Another $75,000 in savings is expected on the backside when containers return from hospitals. The straps also keep containers in an order together, eliminating split shipments.

At DePuy's distribution center, instruments and implants are picked as kits from a vertical carousel directly into the totes. Lids fold over the totes, which are then weighed. If a particular kit weighs only ten pounds, then another of similar weight can also be added to the same tote, as long as the weight falls below the 25-pound handling threshold.

Totes are then combined at the docks using straps with buckle clips. A shipping label is attached to each tote to assure delivery in the unlikely event that strapped totes become separated. The clips are designed with a 1,000 pound stress capacity, and so far, no clip has failed.

The combined totes then ship via overnight service as a single unit. The company is encouraging hospitals to use the strapping system to return the totes as combined units by paying return freight costs. So far, 30–40% are returned this way. As more comply, savings will be even greater.

"The totes have been very good for us," adds DeAmaral. "We expect to get 30–40 trips from each one."