Reusable packaging leaves customer with a good impression

API Foils, a global manufacturer of stamping foils, needed a better protection system for transferring factory rolls from its New Jersey location to sister plants in Kansas and California, where the rolls are converted to widths and lengths per customer specification. In April 2012, the company deployed new reusable protective packaging that cut shipping costs, increased speed and eliminated product damage.

The challenge was retaining the pristine condition of the rolls during shipping by preventing impressions being made on the foil. Before the new solution, the company had been suspending rolls between boards strapped to both ends of the rolls. These end-boards were then strapped to pallets for shipping and storage. The suspension/strapping process took about 10 minutes per roll with the company preparing 25 to 40 rolls a day, each weighing 250 to 450 pounds.

“Then I found a company that made roll protectors out of recycled material,” says Jeff Pendleton, finishing and distribution manager for API Foils. “We could lay two rolls side by side on a pallet, put two more protectors on top and finally lay two more rolls on top of that. It took five minutes to strap, and we would have four rolls done in the time it previously took us to prepare one roll. The only problem was, after using these roll protectors three or four times, they needed to be replaced.”

The recycled protectors also tended to leave impressions in the outer layers of the foil rolls, creating waste. Pendleton wanted to achieve the same ease and results, but with a longer product life and less product damage. Because the product was shipped in a closed-loop system, reusability was also a key objective. The company began testing a set of custom cradles (RollGuard, rollguard.com) made from a high-density, highly durable foam material. The design of the cradles also allowed for one-size-fits-all packaging, replacing as many as five different sized fiber cradles. The lightweight cradles reduced shipping costs, further contributing to the ROI.

“After six weeks of use there was no sign of wear, so in June we ordered the balance,” Pendleton says. “After more than six months, the cradles still look good and we have not had any product loss.”