Shipping its steel stampings for automotive and electric motors was a problem for El-Met-Parts. While the components left the Dundas, Ontario, Canada plant in good shape, they didn't always arrive at their destination in the same condition.

The problem was the single-use, corrugated containers used to ship the parts. Not only were the containers not strong enough to adequately protect the parts or be stacked for shipping efficiencies, there were disposal issues too.

In fact, the corrugated containers were an issue as El-Met-Parts looked to expand into new markets. The continuous expense of replacing and disposing of both the single-use disposable packaging and the wooden base pallets was a cost that the company was increasingly reluctant to pass on to its customers.

"As with any business, it's important for us to work with our customers on all particulars, including the packaging," says Alex Papakyriakou, vice president of quality.

The decision was made to switch to heavy-duty plastic containers with a rigid base and stiff sidewall construction. Damage has been reduced dramatically, creating a 50% cost savings. The reusable containers have also eliminated the disposal issue.

The 2,000-pound capacity containers have a 30 × 32 inch footprint and heights of 25 and 34 inches with four-way fork lift entry. A reinforced lid allows El-Met-Parts to stack the containers up to three high when loaded. Meanwhile, a drop-door option on both sides provides easier access to the contents. Empty containers can be stacked up to six-high.