Navigating the Top Packaging Challenges in the Auto Parts Industry

Case 1: More Efficient, More Protective Packaging for Headlamps

We noticed a customer's suspension pack used to secure and protect headlamps seemed slow and cumbersome. If the products were not perfectly situated in the package, they were easily damaged during transit, costing the automaker time and money.

Through our in-depth analysis and detailed conversations with our partner, Pregis, we identified an innovative solution for the problem: ChamberPak, a specialty air inflation product.

Our solution solved several key challenges for the automaker and helped protect their headlamps.

• Reduced packaging time from one minute and four seconds to 29 seconds
• Minimized product damage in transit, cutting the damage rate from over 5% to under 1%
• Freed up labor force by reducing the number of associates required for packaging

Case 2: Customized Packaging to Prevent Windshield Damage

Another customer was having issues with their windshields becoming damaged during delivery. Following a comprehensive assessment of the packaging, we again worked with Pregis to develop a new design that included using renewable foam to help protect parts during shipment and reduce costs.

Passing the test

To ensure the packaging design would work, we conducted several drop tests to compare it to the previous packaging. In a five-foot drop test, the windshield in the old packaging cracked right down the middle. The new packaging helped protect the windshield in the five-foot drop test and an additional ten-foot drop test. The new design ultimately helped our customer save hundreds of thousands annually in damage costs.

“As a packaging distributor, it’s all about solving problems, including problems a client may not even realize they have,” said Neal Magaziner, General Manager, BradyPLUS.