__________`` V.O.O.P.Z Logistical Packaging. ______* * " ________*`` ____

Friday, January 12, 2007

INTRODUCTION

Ever wonder why this unique name for our blog? If you have noticed from our profile, where you see our names, you may have guessed it! We had used the initials of our surname which are Voo, Ong, Ong, Peh, Zhuang. That's why this blog is named as V.O.O.P.Z....Now u understand, u nincompoop...

Our Gmail address is voopz5@gmail.com because Gmail requires at least 6 characters and our initials alone only have 5, thus "5" is inserted behind our initials. "5" represents our total strength in everything we do, we are 3 human beings and 2 angels(Guess Who??)...You won't understand this if you don't know us well enough...

Ask us questions because our PRINCIPLE is to be more initiative...

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Thursday, January 11, 2007

WHAT IS LOGISTICAL PACKAGING?

From a logistics perspective, the function of packaging is to organize, protect and identify products and materials. Industrial users of packaging strive to gain efficiency and effectiveness of logistics operations.

While the marketing function serves to provide the customers with information about the product and promotes the product through the use of colour and shape.

Logistical packaging involves product identification, ease of handling, efficient use of storage facilities and transportation vehicles, product protection and environmental friendly.

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FUNCTIONS OF PACKAGING

Containment (Unit size): To secure the item from loss or damage if the package breaks open. For instance, carton, pallet.
Protection: To protect the package from damage or loss. For instance, moisture, insects.
Apportionment: To break bulk the bigger unit size to the smaller unit size to suit to customer needs.
Unitization: To unitize smaller unit size to bigger size for the ease of handling. To ensure the efficient use of storage facilities and transportation vehicles. For instance, palletizing cartons into a pallet.
Convenience: To allow the customers to use the products with the least effort.
Communication: To convey any important messages or characteristics of the product to be taken note of. Also, to identify the product.

These will help in reducing costs in terms of:
- reduce the chances of damaging the goods
- save space (more amount of products in the same amount of space)
- reduce on the number of transport journeys (can put more products on one trip)
- durability
- recycling

Therefore, it improves customer service.

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LOGISTICAL PACKAGING UNITS

Unit Load

A unit load is a single item, a number of items, or a bulk material that is arranged and restrained so that the load can be stored, picked up, and moved between two locations as a single mass.

Examples of Unit load: Pallet, Carton, Container

Unitisation

Unitisation is the action taken or the process to package the cargo into unit loads.

For instance, palletisation. There must be a marking on the pallets to show that it is being fumigated before transportation (sea or air). Pallet, however, had some limitations. These include lack of standardization, limited storage space and high cost of materials (especially metal pallet).

Containerisation

Containerisation is the action taken or the process to package the cargo from unit loads into containers which the contents do not have to be unloaded at each point of transfer. It allows efficient transfer of unitized loads among different modes of transportation (air, sea or land).

Container is a large reusable receptacle that can accommodate smaller cartons or cases in a single shipment, designed for efficient handling of cargo which can lower logistics cost in terms of transportation, handling, inventory or packaging cost. It comes in the sizes (lengths) of 10, 20 and 40 feet.

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PACKAGING TESTS

Testing the different types of packages play a vital role in ensuring that the packages are all build to withstand the constant shifting, handling and storing activities that take place. The packages are put through a series of tests which simulates the possible situations that the packages will go through. There are different standard set for the packaging tests. Some examples are American Society for Testing and Materials (ASTM), International Safe Transit Association (ISTA) and National Safety Transit Association (NSTA). The following are the common packaging tests.

Primary Tests

1. Vibration Test

This test requires the operator to determine the acceleration needed to cause the whole package to leave the surface of the shaker platform. This is accomplished by increasing the acceleration of the shaker platform until the package separates far enough to allow a thin and tapered piece of material (metal or wood) that is of about 1/16-inch of thickness to slide between the package and the table surface. Once the frequency of the test is determined, the test continues for another hour.

Vibration Tester

2. Dropping Test

The complete package is released from the required drop height. Sample is dropped once in each of the five different orientations, e.g. dropping the package with the right side of the package facing down. Drop height of the test is determined by the assigned Packaging Group and the relative density of the filler used.

Drop Tester with package Drop Tester

3. Horizontal Impact Test

This test is done to determine the ability of a package to withstand laboratory simulated horizontal impact forces. In this test, the package is being placed on a platform and a machine with a machine arm will impose an impact on the package. The strength of the machine arm is determined by the assigned Packaging Group and controlled by the person doing the test.

Different types of Impact Tester

4. Test of Exposure to Temperature and Moisture

This test is done to determine if the packages are able to withstand the different temperature and moisture exposure. The package will be placed inside the container where it will allow the tester to control the different level of moisture and the temperature level.

Temperature and Moisture Tester

5. Rough Handling Test

There are a lot of different kinds of tests found under this category. For example the cushioning test which determine if the package’s cushion is able to withstand the transmission of shock and vibration, shock test which determine the capability of the package to withstand shock and friction test that determine the capability of the package to withstand friction. Stacking test is also being conducted to ensure that the packaging is able to be stacked together to a certain height.

Machines used for the various tests

6. Compression Test

This test determines the capability of the package to be compressed. The packages are placed on the platform and being compressed using a strength that is found in the assigned Packaging Group.

Machines used to conduct compression test

Additional Tests

Other tests that the packages may need to go through include:

Oxygen Permeability Test: It is testing of the level of oxygen that will be allowed in to the package, usually for packages that contains blood, fishes and etc.
Hydrostatic Pressure/Vacuum Test: This test is only for packages that contain any forms of liquid and is going to be shipped using air transports, e.g. blood samples.
Bursting Test: A test to determine the burst strength of the package.
Radioactive Test: This test is used for packages that needs protection against radioactive rays.
Accelerated Aging Test: A test that determines how long the package can protect the product.

In conclusion, there are many other tests that may need to be included during the testing of the packaging, depending on the types of protection that the product needs.

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MATERIAL HANDLING EFFICIENCY

AND UTILITY

Damage Protection

A master carton is a shippable corrugated carton that contains one or more identical selling units. It is used to protect products from damage due to rough handling while being transported and stored in the logistical system. Pilferage issues are being controlled by utilizing master carton. The selling units contained within a master carton may be individual pieces referred to as ‘eaches’ or a number of smaller multi-piece containers called ‘innerpacks’.

The master carton must meet a minimum single wall corrugated carton specifications of adequate construction for conveyance and floor loading. The carton must contain a seal of certification listing its bursting and weight constraints as defined by the National Motor Freight Classification.

The logistical productivity, utility and efficiency are influenced by the logistical packaging of the products. The entire logistical operations are affected by the packaging utility ranging from the incoming activity to the outgoing activity.

Cube utilization can be improved by utilizing small size of logistical package.

Unitization

Unitization describes the physical categorization of master cartons into one confined load for material handling and transport. An example of unitization includes the palletization concept.

Palletizers are used for load formation. There are three general methods of palletizing unit loads:

1. Manual Palletizing

Operators arrange items into the desired pattern used to form the unit load. Since the ergonomics of loading and unloading are important (e.g., vertically, the prime working zone is between the knees and the chest; horizontally, reaches of more than 24 in. with a load should be avoided), lift and turn tables are often used.

Semi-mechanized palletizers requires operators to arrange items into the desired pattern for each layer of the unit load and a powered device is used to transfer layers onto a pallet and then lower the load for the next layer.

2. Robotic Pick and Place Palletizers

Robotic Pick and Place Palletizers is fully automated device to build unit loads. It is used when flexibility is required (e.g., the "Distributor’s Pallet Loading Problem"). Greatest limitation is capacity, typically 6 cycles per minute; capacity is determined by the number of items handled with each pick operation.

Operators arrange items into the desired pattern for each layer of the unit load and a powered device is used to transfer layers onto a pallet and then lower the load for the next layer.

3. Conventional Stripper Plate Palletizers

Conventional Stripper Plate Palletizers are a fully automated device to build unit loads. It is used when high throughput of identical loads is required (e.g., the "Manufacturer’s Pallet Loading Problem"). Capacity is typically greater (30–180 items per minute) than pick and place because an entire layer is placed on the load at one time; not as flexible as pick and place. Preformed layer of items (cases) are indexed onto the stripper plate (or apron); when properly positioned over the pallet, the apron is pulled out from underneath the layer to deposit the layer onto the pallet.

"In-line" pattern formation (top picture)—flexible patterns are not possible; ideal for high speed operation (up to 180 items per minute); takes up more room (larger machine) than right angle. "Right angle" pattern formation (bottom picture)—very flexible patterns are possible; can handle a wide variety of case sizes and types; limited capacity (up to 80 items per minute); compact design.

Containerization

Containerization is a system of intermodal freight transport cargo using standard ISO containers that are loaded onto vessels and trailers.The types of containerization include rigid containers, non-rigid containers, unit loads, load securing, unit-load platforms, master carton stacking.

Rigid Containers

Rigid containers are simply thicker gages of foil that have been formed into semi-rigid containers to bring the convenience of modern food technology into our homes, schools, and restaurants.

Rigid containers, like foil sheets, provide an ideal barrier to moisture, light, and air. Rigid containers are perfect for holding leftovers and catered food items because, unlike other types of containers, rigid containers do not get soggy or wet and they can be easily recycled.

Rigid Steel Containers

Rigid steel containers feature corner columns made of structural angle or steel tubing, with welded stacking plugs. The columns transmit overhead load weight directly to the floor, thus these containers can be stacked higher than light duty rigid without corner columns. Stacking heights are limited only by the dimensions of the stacks, the lift height of your fork trucks, and the clear height of the facility.

Due to the column transfer of overhead load weight, rigid containers can be ordered with a lower capacity rating than standard containers. Each unit is capacity rated by the weight of the contents of each individual unit, while with other designs the containers would have to be rated to carry the cumulative total weight of all units in a stack.

Rigid steel containers are available in a wide variety of constructions, capacities, sizes, quantities, and colors, to customer specifications. Many options are available, including drop gates, skid bars, for stirrups, fork pockets, crane eyes, etc. Rigid steel containers are an excellent solution to a variety of material handling applications.

Load Securing

Concrete components

Long Steel

Steel Roll

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CHANNEL INTEGRATION

Channel integration is an integration of packaging, material handling and containerization in the warehousing system. Channel integration provides several advantages such as offering seamless customer service across the channels. In addition, leverage process synergies to reduce costs. Enhancing Customer Relationship Management (CRM) sales and service tools and improve cross-sell rates of the products and services. Support aggressive time-to-market demands for introducing new channels/services.

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TRADITIONAL PACKAGING MATERIALS

Corrugated Fibreboard Boxes

The corrugated fibreboard box is able to protect its contents during the transshipment. It is essential to select the appropriate shipping box that will maintain the integrity and performance of the interior packaging from the point of shipment to the ultimate delivery destination.

The corrugated fibreboard has to undergo two laboratory test procedures; the burst test and the edge crush test.

The burst test measures how the board resists bursting pressures applied by an instrument in the lab. The edge crush test measures the ability of the corrugated structure to support a load applied parallel to the fluted direction.

Corrugated fibreboard boxes are classified into the following categorization.

1. Single Faced Fibreboard

Single Faced fibreboard is constructed by gluing a flat sheet of linerboard to a sheet of corrugated material which has been passed through a single facer, thus forming it into a series of arches. This ensures that the corrugations will be firmed and will not stretch or flatten.

2. Single Wall Fibreboard

Single Wall corrugated fibreboard consists of two flat facings and one corrugated member combined in the sequence that follows: a facing, a corrugated member, and another facing.

3. Double Wall Fibreboard

Double Wall corrugated fibreboard consists of three flat facings and two corrugated members combined in the sequence that follows: a facing, a corrugated member, a centered facing, a corrugated member, and a facing.

4. Triple Wall Fibreboard

Triple Wall corrugated fibreboard consists of seven sheets of paperboard combined in the following sequence: a facing, a corrugated member, an inner facing, a corrugated member, an inner facing, a corrugated member, and a facing.

UN Fibreboard Boxes

The UN Fibreboard Boxes are designed specifically for transporting dangerous goods. These boxes are suitable for road, air and sea transport. It acts as an outer packaging which can be used to indulge inner packaging such as bottles, cans and jars.

Burlap Bags

Burlap bags are rugged containers which can be used for a variety of applications due to its strength, durability and bio-degradability features. Some of the more common applications are sand bags, grain sack races or quality bags with jute draw strings for presentations.

The competitive advantage of burlap bags are being its flexibility, durability and biodegradable functions. In addition, it is economical and most desirable for rip-rap application. Burlap bags are ideal for shipping and storing metal and hardware products. It absorbs moisture, oil and grease while ensuring air circulation.

Multi-Wall Paper Bags

Multi-wall paper bag is an eco-friendly packaging which is fully recyclable. It is used for packaging of tea, dry minerals, carbon black, cement and various other products.

The bags are made of multiple layers of kraft paper which gives it great strength for being a strong package. The inner layer of the bag is laminated or specially coated to protect the contents from harmful contamination and to keep the contents fresh. Multi-wall paper bags are scientifically proven to preserve freshness, reduce infestation, resist moisture, lock in odors and to reduce or eliminate chemical preservatives.

Steel Cans

Steel cans are made from tinplate steel, which is produced in basic oxygen furnaces. A thin layer of tin is coated onto the can's inner and outer surfaces. This is to prevent rusting and to protect food and beverage flavours as it is important for steel cans to be free from any contaminants.

Steel cans are commonly used for containing food and beverage, paint, aerosols, solvents and other flammable and combustible products. Steel cans account for more than 90 percent of food cans, and more than 600 shapes, styles and sizes of containers are used. Steel cans can be recycled for next consumption which in turn integrated into cost reduction programme.

The element in the widespread use of steel is its diversity in material properties and exceptional formability. Packaging steels can be bent, shaped and folded into a multitude of configurations. Deep drawing, flattening and forming characteristics offer endless possibilities for applications that require strength and lighter weight. Steel cans allow superior exterior designs that cater to customers’ demands. The painted cans above appear to be more attractive than the non painted ones. Customized painted cans are able to drive the market with ascending sales.

Shrink Wrap

Shrink wrap is used for load stabilization. In shrink-wrapping, a film or bag is placed over the load and then heat is applied to shrink the film or bag; allows irregular loads to be stabilized; manual or automatic; most shrink-wrap applications are being replaced by stretch-wrapping. In stretch-wrapping, a film is wound around the load while the film is stretched; allows irregular loads to be stabilized; manual or automatic; as compared to shrink-wrapping, stretch-wrapping has lower material, labor, and energy costs.

Cushioning - White Poly Foam Wrap Non-perfed

The low-density polyethylene foam is constructed from millions of tiny, closed-air cells to provide superior cushioning, surface protection, and simple void filling. Compared to other foams, polyethylene foam is tough, crushproof, and prevents bottoming out.

Plastic Strapping

The high-quality plastic strapping is economical and is ideal for unitizing and palletizing shipments. Plastic strapping that shrinks is used to keep loads from becoming loose during shipment.

Pails

1. Plastic Pails and Lids

The plastic pails are dedicated to safe storage and shipment of products. It is durable and has a high density polyethylene construction that is able to withstand extremes temperature up to 82.2°C (180°F). Plastic pails range in sizes from 1 gallon to 6.5 gallons and are used to transport a variety of products for industries including paints, food, construction supplies, janitorial supplies, lubricants, specialty chemicals, pool products, pet products, and retail applications.

2. Lifelatch Pails

These UN approved Lifelatch Pails are ideal for packaging solids. They come with a screw on lid and are available in a variety of sizes and colors.

3. Biohazard Lifelatch Pails

Biohazard Lifelatch Pails offers a variety of sizes that range from 1 gallon to 6.5 gallons. It is approved for the collection and shipment of biohazard waste. It is produced with a user friendly screw on lid for easy stack ability and storage.

4. Plastic Open-headed Pails

The plastic openhead pails are manufactured in a variety of sizes ranging from 1 gallon to 4.25 gallons. The plastic openhead pails provide non-gasket, easy open covers or standard covers features.

5. Plastic Tighthead Pails

The plastic tighthead pails have threaded bodies and covers which allow the cover to be screwed onto the pails. The locking teeth prevent the cover from unleashing the pails in transit.

6. Steel Pails

Steel pails can transport safely and economically almost all classes of hazardous materials. Its resistance to fire makes it an ideal package for flammable and combustible liquids. Steel pails are strong, safe, versatile and eco-friendly. These benefits provide steel pail customers with cost savings and special marketing advantages. Steel pails are environmentally friendly as it can be recycled and the industry makes use of its scrap in producing new steel.

Steel pails are able to accept the widest range of products because of its strength, high UN performance and array of compatible interior linings and fittings. In addition, steel pails ensure safety in the field, classified as a valuable product and are stackable in the warehouse.

7. Tighthead Steel Pails

Tighthead Steel Pails are available in sizes ranging from 3 gallons to 20 liters. The tighthead steel pails are UN rated for packaging of hazardous materials such as solvents and other chemicals. Pails are available with various fittings in the head and with various exterior colors and interior linings.

Drums

1. Plastic Drums

Plastic drums are made from a high molecular-weight, high-density polyethylene resin and manufactured to high standards of quality and consistency. This material makes the drums extremely strong and rigid, allowing easy handling and low shipping costs. Plastic drums provide savings in warehousing storage space because they are stackable and can be stored outside without rusting. In addition, total packaging costs are decreased because plastic drums are reusable.

2. Tighthead Plastic Drums

Tighthead Plastic Drums are available in sizes of 15 gallons, 30 gallons and 55 gallons. They are available with standard size fittings. The drums are UN/FDA approved, they are approved for domestic and international shipments. In addition, tighthead plastic drums are reusable, recondition able, and recyclable.

3. Plastic Open-Headed Drums

Openhead plastic drums are approved for domestic and international shipments. The features of openhead plastic drums include heavy-duty construction, molded in hand holds, sturdy interstacking, UN/FDA approval, locking metal ring, and they are reusable, recondition able, and recyclable.

4. Steel Drums

Steel drums are ideal for all types of liquid chemicals including hazardous chemicals. Steel drums are available in sizes of 30 gallons and 55 gallons. The types of steel drums include lined or unlined drums, tightheads, openheads (with a variety of lid and ring types), UN/DOT certified drums, and 55 gallon hazardous waste drums. Steel drums can be used by a number of oil, solvent and chemical companies. In addition, the openhead hazardous waste drums can be used for a wide variety of environmental clean-up situations.

5. Steel Open-Headed Drums

Steel Open-Headed drum has an open top with a lid and is primarily dedicated to dry products. Steel Open-Headed drums are constructed using high quality carbon steel. These open head containers meet UN design type testing requirements.

6. Steel Closed-Headed Drums

Steel Closed-Headed drums are utilized for containing liquid products. It does not have a lid, it is filled with an open hole (as shown in the picture above). Steel drums are designed, manufactured, and certified to meet UN requirements under DOT 49 CFR. They are supplied with rust-inhibitor interior or chemical-resistant epoxyphenolic lining.

7. Poly Drums

Poly drums are manufactured in sizes of 30 gallons and 55 gallons drums, both available as tighthead or openhead drums. These are ideal for racing fuel, automotive fluids, perfumes, soaps, food grade additives, etc. Poly drums are customized for animal feeders and water tanks, deer pellet feeders, etc.

8. Fibre Drums

Fibre drums will are used for storage and transport of dry products. It is ideal for transporting food or other hygienic products. Fibre drums are also suitable for transporting and storing a wide variety of chemicals, powders, pastes and solid products and also provide excellent protection for textiles, films, adhesive tapes, pharmaceuticals and plastic resins. Fibre drums are available in capacities up to 500 litres. In addition, drums are certified to verifiable levels of cleanliness.

9. Salvage Drums

Salvage drums are designed to house damaged and leaking drums and are regulated by the Department of Transportation (DOT). If a company or shipper has a leaking drum or solvents used on a spill or leak and they wish to ship them across public roads, salvage drums must be used. The Salvage Drum is a drum which is larger than the leaking drum and allows the leaks to be placed inside the salvage drum for safe shipment to a disposal or treatment facility. Salvage drums must pass, at a minimum, standard UN requirements for drums shipping solids as well as 3 PSI air leak proof test.

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