Cosmetic industry optimizes operations replacing all Sealed Air Systems with the quicker, more efficient Pregis AirSpeed HC Systems and packaging products.
Pregis and IPS Packaging approached the customer to see if they would consider a foam-in-place (FIP) alternative including the AirSpeed HC system in its distribution center’s repacking area. The customer had been using Sealed Air’s Ultralite low-density foam in conjunction with the Instapak FIP delivery system to protect its high-end skin, bodycare, and fragrance products. However, what started off as a review of one aspect of the packing operation, turned into a full-blown survey of the entire distribution center - products, applications, and operations.
Packaging Optimization Solution and Results
Repacking - The first production area was put to the test. The AirSpeed HC system was trialed against Sealed Air’s 3/16 inch bubble wrap. Upon a close review, the customer discovered they were using so much bubble that they could get better, more cost-effective performance by switching to medium Hybrid Cushioning. Inventory space and labor were minimized because it was no longer necessary to drag bubble rolls across the plant floor to the repacking area. Another compelling component of the conversion was Renew’s fomulation which enabled the company to promote its environmental benefits to its consumers by inserting a card in the box.
Internet Fulfillment Orders - The customer was using Sealed Air’s Korrvu suspension pack (a structure which combines corrugated and film to suspend and immobilize the product). They had been experiencing multiple problems with this pack: the components take up a fair amount of warehouse space; it’s expensive and the damage rate was too high. To make the HC/Renew solution even more efficient and viable, autobins with sensors were installed to automatically trigger the AirSpeed HC unit to produce more cushioning material when a low level is reached. By placing the autobins in front of each HC unit, the need to rewind and manually transfer bundles is eliminated.
Inline Packing - All products that come down the conveyor belt were previously being packed with Instapak FIP. By completely changing over to the AirSpeed HC system, the customer was able to free up floor space previously used to store the chemical drums and avoid questions regarding foam’s environmental impact.
The end result was total replacement of Sealed Air’s products and equipment with AirSpeed systems and materials.
- Biodegradable
- Made with significantly less plastic resin than other packaging material
- 100% recyclable
- Made with recycled raw material content
Total Packaging Cost Summary
- Material = significant reduction in plastic resin when switching to HC Renew
- Space = Increase in work space due to the elimination of bulky bubble rolls
- Labor = Reduction in labor due to lack of movement of bulky, cumbersome bubble rolls
- Damage = Complete Reduction in Damage to 0%
