Packaging Evolution of Crafco’s Packaging Tom Kelly Charley Grady

Code 3 Box Specifications Labeled in accordance with OSHA, GSH and specification requirements Lined with a specially-blended bag to melt cleanly at recommended application temperatures Exact box weights range from 26lb. to 40lb. per box We have new sales staff from other industries. Need to explain what the acronyms GSH, WRA, ECT mean. Also a reminder as to why OSHA has requirements for packaging.

Code 3 Box Specifications Code 3 packaging dimensions are approximately 8 1/2”H x 12 1/2”L x 9 1/4”W Code 3 boxes are single wall boxes using WRA glue to resist moisture Designed to meet or exceed 55 ECT requirements to ensure maximum pallet stability strength

Code 3 Box How We Got Here Sealant Packaging started out in larger double wall single and twin compartment boxes with weights ranging anywhere from 45lb – 70lb These packages were assembled manually using 2” staples to close the top and bottom of each package. Staples getting in to melters, maximum box weight concerns with OSHA safe lifting recommendations and the desire to automate our packaging lines led to the original code 3 box design in the mid 1990’s.

Code 3 Box How We Got Here In 2011 the code 3 box was changed over from a double wall to a single wall designed to meet, or exceed 44 ECT requirements to make all of our code 3 packaging uniform among our 5 production facilities at that time. In 2013 the code box was upgraded in design to meet, or exceed 55 ECT requirements to prevent box bulging and pallet stability issues over long storage times. In 2015 the code 3 package was switched over to an “exact weight” where it is today with each box filled to a specific net weight printed on the top of each box. We our currently modifying our code 3 package dimensions at each facility to ensure uniformity and try to maximize the amount of products that we can safely fill with 30lb. Net of sealant. This new design will also include the use of an inside manufactures glue joint.

Code 3 Bag How We Got Here The current code 3 bags we use are made using either a cast, or blown high density polypropylene formulation that we have worked with several manufactures over the past 5-7 years to improve both the melt ability and the durability of our bag. Our process temperatures in production require us to use a durable bag which can handle up to 280F pouring temperature without the risk of “leakers”. Our current bag designs are formulated to work well in our production processes while at the same time melt quickly and cleanly out in the field at recommended application temperatures.

Code 3 Blown Bag Screen Test results

Code 3 Cast Bag Screen results

Code 3 Pallet Configuration The standard code 3 pallet consists of 75 boxes of material per pallet, 15 boxes per layer, 5 layers per pallet. Interlocked stacking for pallet stability Standard 48” x 40” x 4 way new, or used pallet with top gaps not to exceed 1” .004 plastic bottom sheet, .004 pallet bag w/ 1year UVI, .006 white cap sheet and 115 ga. stretch wrap w/ 1 year UVI used to protect the corrugated packaging for at least 6 months and up to 1year from date of manufacture. Exact Pallet weights range from 2,100lb. ( 26# per box ) to 2,250lb. ( 30# per box ) There are also separate packaging codes for products packaged in code 3 at 2,100lb. ( 35# per box and 2,400lb. ( 40# per box ).

Code 3 Pallets How We Got Here The original code 3 pallet design was a new 42” X 42” X 2 way pallet designed to run thru our new automatic palletizer systems. This pallet consisted of 9 top deck boards spaced evenly across the top of the pallet, 3 stringer boards and 3 bottom boards In 2014 the code 3 pallet design was converted over to a #1 used, or new 48” X 40” X 4 way pallet design to allow for our new/current pallet configuration. Slight alterations have been made since then to get to our current day specifications.

Code 3 Pallet Configuration How We Got Here Original Code 3 pallet configuration started as 72 boxes per pallet,12 boxes per layer stacked 6 layers high labeled with the net pallet weight of each pallet not to exceed 2,880lbs. These pallets In 2014 we changed this configuration to 75 boxes per pallet, 15 boxes per layer, 5 layers high. This gave us a shorter, wider pallet which made for easier handling, storage and better pallet stability which we see today.

Code 3 Pallet Protection How We Got Here Our bottom sheets protection started off as a 42” X 42” X .0025ml plastic bottom sheet stapled to the top of each pallet to prevent moisture from wicking up thru the wooden pallet and in to the bottom layer of boxes which will cause box failure and pallet stability issues. In 2014 this bottom sheet was changed to a 48” X 40” wax coated corrugated sheet placed face down stapled to the top of each pallet. This design did not hold up as well as anticipated during long periods of storage and exposure to continuous rain & snow. After a few cycle of exposure the wax wore off allowing the moisture to penetrate up in to the bottom layer of boxes resulting in box and pallet stability failure. In 2015 this bottom sheet was changed to the 48” X 40” X .004ml plastic sheet that is still in use today.

Code 3 Pallet protection How We Got Here The original code 3 pallet bag was a .003ml gusseted pallet bag sized for the original code 3 pallet configuration manufactured with 1 YR UVI protection. This 1 YR UVI protection was added after months of testing both in our yards and UTV testing in the lab. It is a critical part of our pallet bag which allows us to get the maximum storage life out of these as possible. The pallet bag was upgrade to a .004ml bag with 1YR UVI in 2000 to help extend the life of our packaging. This 1 YR UVI is from date of manufacture, but in most case we can expect a minimum storage life of 6 months and even up to 9 months in some conditions before deterioration.

Code 3 Pallet protection How We Got Here Our original code 3 cap sheets were 60” X 60” X .006ml white plastic cap sheet manufactured with 1YR UVI protection used to provide additional UVI protection to our top box print and the top of the pallet bag. In 2014 the cap sheet was changed to a 48” X 56” X .006ml white plastic cap sheet manufactured with 1 YR UVI to accommodate our new pallet design. Production samples of both our pallet bags and top cap sheets are taken randomly and tested to assure that these materials are meeting our UVI requirements. All code 3 packaging pallets are wrapped by automatic stretch wrapping machines applying 3 layers of wrap on the top with a minimum 3” overlap over the top of each pallet and 3 layers on the bottom of each pallet using 20” X 115 Ga. Stretch film manufactured with a 1 YR UVI protection that has been in use since the late 1990’s. This heavy gauge film has shown to resist the elements of extreme summer heat and harsh winter seasons providing us with the protection we need for the code 3 packaging.

Code 3 Automated Packaging Code 3 automated packaging started in Chandler, AZ. 1994. In January 2018 we will have 5 sealant facilities running code 3 packaging using automated systems and 1 semi-automated. Standard 8HR 2 shift capacity by facility (No Overtime) : Allentown, PA = 40,000,000 lbs. Chandler, AZ. = 40,000,000 lbs. Cheyenne, WY. = 20,000,000 lbs. based on PM production volume of 20,000,000 lbs. Halls, TN = 40,000,000 lbs. Naples, TX = 40,000,000 lbs. Youngstown, OH. = 40,000,000 The addition of our Naples, TX. Facility Sealant Production System in January will result in a total company-wide capacity of more than 180 million lbs. per year for our code packaged sealants.

Original Code 3 Pallet vs. New Code 3 Pallet

Questions?