Dunnage reduces damage

Cooper Hand Tools increased efficiency and reduced shipping weight when it dispensed with paper in favor of foam-in-bag packaging.

By Sara Pearson Specter, Editor at Large -- Modern Materials Handling, 12/1/2004

At its distribution center, in Apex, N.C., Cooper Hand Tools fills orders for its industrial, commercial and consumer tools from adjustable wrenches to soldering guns. Unfortunately, the packaging process was not as efficient as it could be. Furthermore, the paper packaging wasn't adequate to sufficiently protect the tools, which are distributed worldwide.

"We were using paper to package our tools, but changing the heavy paper rolls put an unneeded strain on our packaging operators. We needed packaging materials that would alleviate exertion for the operators, but we didn't want to spend more per carton," recalls David Looper, operations supervisor for Cooper Hand Tools.

The company turned to a foam-in-bag product (Sealed Air, 201-712-7000) capable of expanding up to 280 times from its liquid state.

The automated system dispenses a controlled amount of foam into a sealed bag. When the bag is placed in a carton, the foam expands to conform to the shape of the contents, creating a protective cushion. Within seconds, the foam sets and locks the products in place. Unlike the paper dunnage, the solid foam cushion prevents items from shifting during shipment, greatly reducing the risk of damage.

After testing the system for a month with cartons containing 20 to 25 tools, Cooper discovered that the weight of each carton was reduced by half a pound compared to cartons packed with paper dunnage. In addition, the new packaging improved productivity, allowing for the processing of more than 1,200 packages per day with only one operator.

Furthermore, the packaging operators used to exert a tremendous amount of energy changing the paper rolls 15 to 18 times a day, adds Charlie Schlegelmilch, distribution manager. In contrast, the rolls of bags are half the weight of the paper rolls and only need to be replaced every other day. The foam formulation tanks need to be changed every four to five weeks.

"The foam-in-bag system not only allows for greater productivity, but the packages are also well received by our customers," Schlegelmilch continues. "The foam cushions help prevent damage to the tools during shipment and can be reused by our customers, if needed."

Since switching to the new packing system, Cooper has recorded fewer returned items. However, if a customer decides to send back tools, the foam packaging can be reused to re-package the tools and help ensure their safe arrival.

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(Modern Materials Handling Caseboook - Mid-October 2004)