Case Studies

Returnable Packaging System for Building Products

Opportunity
A producer of extruded building materials was introducing a new product line of exterior building finishes. The products offered a unique handling challenge because different product lengths varied from 8 feet to 26 feet. The original packaging concept was a wooden crate, requiring stitching lumber together to accommodate the varied lengths of products. It was costly in materials and labor, and there were also difficulties in moving and handling such large crates.

Solution
Through financial modeling, it was determined that a reusable racking system could be cost effective. The system would need to safely and cost-effectively contain the products through the warehousing and distribution process. In the field, easy unloading was desirable. The racks would then be grouped, collapsed, and returned to the original manufacturing site.

Results
Adalis designed a lightweight steel racking system that was adaptable to the varied lengths and effectively protected the products through distribution. Innovative features were incorporated into the long racks to facilitate the moving and handling of the filled containers. The racks are stackable, collapsible and minimized space in the warehouse. The new racks have handling and weight advantages as well as financial benefits versus the original wood crate. The new system also reduced waste and disposal issues at the job site.