CHAPTER 5 Protective Packaging and Materials Handling

5-2 Product Characteristics F Physical Characteristics –Density of bulk materials –Ability to withstand exposure to elements –Respiration F Chemical Characteristics –Incompatible products –Products requiring chemicals F Characteristics must be made known to consumers

5-3 Product Characteristics (Cont.) F Hazardous Cargo –Explosives –Compressed gases –Flammable liquids –Oxidizers –Poisons –Radioactive materials –Corrosive materials

5-4 Hazardous Cargo Regulations Photo: John Long

5-5 Product Characteristics (Cont.) F 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 F Metric System Usage

5-6 Packaging F Building-blocks concept –Smallest unit is consumer package –Each unit is stocked within the next larger one to protect the product F Promotional functions of boxes

5-7 The Building- Blocks Concept of Packaging: A Summary

5-8 The Building-Blocks Concept of Packaging? Photo: Earl Kimbrough

5-9 Packaging (Cont.) F 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

5-10 Checklist for Box Users

5-11 Boxmaker’s Certificate (BMC)

5-12 Boxmaker’s Certificate (Cont.) Photo: Cody Guthrie

5-13 Packaging (Cont.) F Package testing –Vibrations –Dropping –Horizontal impacts –Compression –Overexposure to extreme temperatures or moisture –Rough handling

5-14 Results of Compression Test

5-15 Packaging (Cont.) F 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

5-16 Packaging (Cont.) F 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

5-17 Examples of Shipping Labels

5-18 Example of Shipping Label Photo: Cody Guthrie

5-19 A Handheld Laser Scanner Scanning Labels on a Pallet Load of Product Sitting in a Warehouse Rack

5-20 Unit Loads in Materials Handling F 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 –Pallets rentals in wood or plastic –Should be less than 50 pounds—difficult with plastic –Metal also used in closed loop systems

5-21 Unit Loads in Materials Handling (Cont.) F A unit load is one or more boxes secured to a pallet or skid so that boxes can be handled by mechanical means F Unitization describes this type of handling F Slip sheet can be used in place of pallet –Saves vertical room –Requires more care when moving

5-22 Unit Loads in Materials Handling (Cont.) F Advantages –Additional protection –Pilferage is discouraged –More fragile items can be stacked inside the load –Mechanical devices can be substituted for hand labor F Disadvantages –Provides large quantity that sometimes is of limited value to resellers dealing in smaller quantities –Must use mechanical or automated device to move

5-23 A Battery Powered Lift Truck Used for Stock Picking

5-24 Unit Loads in Materials Handling (Cont.) F 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

5-25 Air Carrier Containers Photo: Georgia Aquarium

5-26 Various Types of Intermodal Surface Containers

5-27 Unit Loads in Materials Handling (Cont.) F Equipment loading –Load-planning –Bracing –Inflatable dunnage bags –Load is subjected to forces u Vibration u Centrifugal u Roll u Pitch

5-28 Materials Handling F Materials handling refers to how the materials or products are handled physically F How the products are handled depends on whether they are packaged or in bulk F Handling may change the characteristics of the product

5-29 Materials Handling Principles F Orientation F Requirements F Integrated system F Standardization F Just-in-time F Unit load F Minimum travel F Space utilization F Ergonomics F Energy F Ecology F Mechanization

5-30 Materials Handling Principles (Cont.) F Automation F Flexibility F Simplification F Gravity F Safety F Computerization F Systems flow F Layout F Cost F Maintenance F Obsolescence F Team solution

5-31 Materials Handling in the Supply Chain F Products can move throughout the entire supply chain F Bar codes, two-dimension codes, radio- frequency codes systems facilitate integration throughout the supply chain