Protective Packaging and Materials Handling CHAPTER 5 Protective Packaging and Materials Handling

Learning Objectives To know how product features affect packaging and materials handling To identify the functions performed by protective packaging To analyze the utilization of unit loads in materials handling

Learning Objectives To appreciate how the environmental protection movement has affected packaging and package choice To learn materials handling principles

Protective Packaging and Materials Handling Key Terms Building-blocks concept Bulk materials Compliance labeling Key Terms Ergonomics Materials handling Package testing

Protective Packaging and Materials Handling Key Terms Pallets Recycled content Slip sheet Key Terms Unitization Unit loads

Product Characteristics Physical Characteristics Density of bulk materials Ability to withstand exposure to elements Respiration Chemical Characteristics Incompatible products Products requiring chemicals Characteristics must be made known to consumers

Figure 5-1: Portion of Fabric Care Label for Levi’s Jeans Sold in Japan

Product Characteristics Hazardous Cargo Explosives Compressed gases Flammable liquids Oxidizers Poisons Radioactive materials Corrosive materials

Product Characteristics Environmental Protection Reduce packing materials used Use packaging materials that are more environmentally friendly with recycled content Use reusable containers Retain or support services that collect used packaging and recycle it

Product Characteristics Packaging Scrap Disposal Pallet shredder Metric System usage

Figure 5-3: A Pallet Shredder Designed to Reduce the Cubic Volume of Wooden Pallets and Crating So That They Cost Less to Transport

Packaging Building-blocks concept Promotional functions of boxes Smallest unit is consumer package Each unit is stocked within the next larger one to protect the product Promotional functions of boxes

Packaging Protective functions of packaging Enclose materials Restrain materials from undesired movement Separate contents to prevent undesired contact Cushion contents from outside vibrations and shocks Support the weight of identical containers stacked above Position the contents to provide maximum protection Provide for uniform weight distribution Provide exterior surface for labeling Be tamperproof Be safe for consumers or others

Figure 5-7: Checklist for Box Users

Figure 5-9: Boxmaker’s Certificate (BMC)

Packaging Package testing Vibrations Dropping Horizontal impacts Compression Overexposure to extreme temperatures or moisture Rough handling

Figure 5-10: Results of Compression Test

Packaging A package system requires 3 types of information to design Severity of the distribution environment Fragility of the product Performance characteristics of various cushion materials

Packaging Labeling Retroflective labels Batch numbers Weight Specific contents Instructions for use Information to allow passage through customs Compliance labeling One- or two-dimensional bar codes Smart labels or RFID labels

Figure 5-14: Examples of Shipping Labels

Figure 5-16: A Handheld Laser Scanner Scanning Labels on a Pallet Load of Product Sitting in a Warehouse Rack

Unit Loads in Materials Handling Basic unit is a pallet or skid Lumber is expensive so firms want pallets returned Provides cushioning effect in transport Quality of pallets varies widely Chep USA rents pallets in wood or plastic Should be less than 50 pounds—difficult with plastic Metal also used in closed loop systems

Unit Loads in Materials Handling A unit load is one or more boxes secured to a pallet or skid so that boxes can be handled by mechanical means Rainbow pallet load Unitization describes this type of handling Slip sheet can be used in place of pallet Saves vertical room Requires more care when moving

Unit Loads in Materials Handling Advantages Additional protection Pilferage is discouraged More fragile items can be stacked inside the load Mechanical devices can be substituted for hand labor Disadvantages Provides large quantity that sometimes is of limited value to resellers dealing in smaller quantities Must use mechanical or automated device to move

Figure 5-19: A Battery Powered Lift Truck Used for Stock Picking

Unit Loads in Materials Handling An intermodal container holds the unit load Interchangeable among rail, truck, and water carriers Air carriers usually use irregular shaped containers made to fit fuselage

Figure 5-21: Various Types of Intermodal Surface Containers

Unit Loads in Materials Handling Equipment loading Load-planning Bracing Inflatable dunnage bags Load is subjected to five forces Vibration Centrifugal Retardation Roll Pitch

Figure 15-25: The Building-Blocks Concept of Packaging: A Summary

Materials Handling Materials handling refers to how the materials or products are handled physically. How the products are handled depends on whether they are packaged or in bulk Handling may change the characteristics of the product

Materials Handling Principles Orientation Requirements Integrated system Standardization Just-in-time Unit load Minimum travel Space utilization Ergonomics Energy Ecology Mechanization

Materials Handling Principles Automation Flexibility Simplification Gravity Safety Computerization Systems flow Layout Cost Maintenance Obsolescence Team solution

Materials Handling in the Supply Chain Products can move throughout the entire supply chain Bar codes, two-dimension codes, radio-frequency codes systems facilitate integration throughout the supply chain