Protective Packaging and Materials Handling

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

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

Packaging Building-blocks concept Promotional functions of boxes Smallest unit is consumer package Each unit is stacked 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

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

Packaging Designing a package requires 3 types of information Severity of the distribution environment Fragility of the product Performance characteristics of various cushion materials

Unit Loads in Materials Handling A unit load is one or more boxes secured to a pallet or skid. The term “unitization” describes this type of 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; used in closed-loop system Should be less than 50 pounds—difficult with plastic Metal also used in closed loop systems

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

Unit Loads in Materials Handling Slip sheet can be used in place of pallet Saves vertical room Weighs far less than pallet 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

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 – understand entire system, relationship to other systems and physical limitations Requirements – expected performance Integrated system – coordination of all storage & handling systems Standardization – of package sizes Just-in-time – products not moved until needed Unit load – handling materials in large blocks Minimum travel Maximize space utilization Ergonomics – protect workers from difficult or repetitive functions Energy efficiency Ecology – environmental friendly Mechanization – substitute machines for humans Automation – very capital intensive; less flexible Flexibility

Materials Handling Principles Simplification – avoid overly complicated systems Gravity – rely on gravity to move materials when possible Safety Computerization Systems flow Systems flow Layout Cost Maintenance Obsolescence Team solution

Problems in Materials Handling