United States
Reusable Packaging Right-Sized:
How to Evaluate the Right Reusable
Container for your Product’s Protection,
Internal Handling and Logistics
By:
David R. McCulloch
VP and Managing Director,
Packaging Systems Division
Plastics Group
Schaefer Systems International, Inc.
© 2014 SSI Schäfer
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How do we select a Reusable Container
System?
What are we shipping?
How will we protect it?
How are we shipping it?
How will it be handled?
Where is it being shipped?
How many, how often?
Etc., etc., etc……
The choices are endless, but ONE THING
drives the choice “Logistically”
© 2014 SSI Schäfer
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Packaging is not driven by the Product but by LOGISTICS!!

In school I was taught that packaging is driven by the need
to protect the Product being Distributed.
–
Using the Primary / Secondary / Tertiary Principles

Primary = DUNNAGE

Secondary = Container

Tertiary = Pallet / Skid / Palletized Load
• The Primary Tool for Calculating all of this is a Cube
Analysis Process, one popular is CAPE™.

So you say, what is the problem?
–
CUBE in the DISTRIBUTION CHAIN, which was highlighted quickly
when Gasoline and Diesel Fuel went over $ 4.00 USD / Gallon.

© 2014 SSI Schäfer
You pay for Correct Reusable Packaging only ONCE, you pay for
freight forever!
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Packaging is driven by LOGISTICS, not the Product!!

What is taught in school is in reverse order for Distribution
and Logistics!! Many Consider Packaging & Method of
Distribution last!
–
Using the Primary / Secondary / Tertiary Principles, we add a
CRITICAL Fourth level or unit, and call it Quaternary.

Primary = DUNNAGE

Secondary = Container

Tertiary = Pallet / Skid / Palletized Load

Quaternary = Truck / Train / Ship
• We still are working in Reverse, for Logistics:

© 2014 SSI Schäfer
Note:
Automated Storage Systems: Packaging 1st =
Money $$$$ Saved in your System Installation
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How am I shipping my product?
© 2014 SSI Schäfer
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How do I determine what I need with So Many Choices?
© 2014 SSI Schäfer
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AIAG Straight Wall Container Choices
 Collapsible / Stackable
© 2014 SSI Schäfer
 Stack Only
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
Product Protection - Considerations
Dunnage for Part
 ESD for Electro Static
Protection / Separation
Sensitive Parts
© 2014 SSI Schäfer
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Custom Steel Racks and Dunnage Designed for Part

Work-In-Process / Washing
© 2014 SSI Schäfer

SolidWorks 3D / Glass Rack
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Economic Benefits / Cost Evaluation (RPA)
Reusable packaging can reduce costs throughout the
supply chain. Example, Reusable Packaging Systems:
Reduce overall packaging costs
Deliver rapid ROI
Reduce costly product damage
Reduce labor costs
Reduce inventory, therefore requiring less space
For the purpose of this presentation we will assume
that using Reusable Packaging has been cost
evaluated and determined to be feasible, using the
Cost Evaluation tools on RPA www.reusables.org or
www.usereusables.com/cost
© 2014 SSI Schäfer
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Packaging is driven by LOGISTICS, not the Product!!

What is taught in school is in reverse order for Distribution
and Logistics!! The Correct Decision Order is:
–

Using the Primary / Secondary / Tertiary / Quaternary Principles,
considering Method of Distribution First!!

Primary = Truck / Train / Ship

Secondary = Pallet / Skid / Palletized Load

Tertiary = Container

Quaternary = Dunnage (if Needed)
We are no longer working in Reverse from Logistics!!!
–
© 2014 SSI Schäfer
Savings will be had everyday your products are distributed with a
Package Developed from the Method of Shipment backwards! This
is the only way to Maximize Cube Utilization and Minimize Freight.
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Shipping via Sea Container?
•
•
© 2014 SSI Schäfer
Common Pallet Sizes:
• 1200 x 1000 mm, 1190 x 1140 mm and 1200 x 800 mm
Common Containers sizes vary – standards being evaluated
• All are metric (mm) based on one of the Pallet sizes above
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Shipping via Tractor-Trailer?
• Most common today is 53’ High Cube (110”)
•
•
Common Pallet Sizes:
• 48 x 45 Inch, 48 x 40 Inch and 32 x 30 Inch.
Common Containers sizes vary – Standards vary by Industry
• Most are by Inches based on one of the Pallet sizes above
© 2014 SSI Schäfer
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For our Example, we will use the following
Criteria:
We are shipping product from our
Manufacturing Plant to our Customer
Personalization / Distribution Center.
Product will ship via full 53’ Truck loads using
48 x 45 Pallet and Tops, and hand held
Containers. Mixed with other products using
compatible palletized products.
So how do we select the best container?
© 2014 SSI Schäfer
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Tape Measure with the Printed Carton / Dunnage / Quaternary Unit
© 2014 SSI Schäfer
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Container Cube Calc ©
Part Name:
Part Number:
Unit
Length
Width
Height
Depth
Part
Weight
Tape Measure
Container Sizes: Length & Width - NF Totes
Container Sizes: Height - NF Totes
16IMBLKYEL
OD:
48.0 36.0 32.0 24.0 22.4 15.0 12.0
7.5 4S
4C
5S
7S
7P/C 8S
9S
11S 11P/C 14S 14C
Dimensions
ID: (In)
45.3 33.3 29.3 21.3 20.4 12.9
9.4
5.3
3.3
2.8
4.3
6.8
6.3
8.0
8.8 10.3
9.8 13.8 13.3
Eng. (in.) Met. (mm) ID: (mm) 1151
846
744
541
518
328
238
135
83
71
109
173
160
203
223
261
248
351
338
3.18
81
14.27 10.49 9.23 6.71 6.42 4.07 2.95 1.67 1.03 0.88 1.35 2.15 1.98 2.52 2.77 3.24 3.08 4.35 4.19
1.64
42
27.67 20.34 17.89 13.01 12.45 7.89 5.72 3.25 2.00 1.71 2.62 4.16 3.85 4.88 5.36 6.28 5.96 8.44 8.13
3.04
77
14.91 10.96 9.64 7.01 6.71 4.25 3.08 1.75 1.07 0.92 1.41 2.24 2.07 2.63 2.89 3.38 3.21 4.55 4.38
0
0
Lb.
Kg.
Option 1
Option 2
Option 3
Option 4
Option 5
Option 6
0.5
0.23
Len. Wid. Hgt. Len. Wid. Hgt. Len. Wid. Hgt. Len. Wid. Hgt. Len. Wid. Hgt. Len. Wid. Hgt.
1
Tote Size (Inches) L x W x H
12
15
4
12
15
5
2
# of Parts per L x W x H
3
4
2
3
4
2
3
Part Orientation L x W x H
77
81
41
77
81
41
4
Number of Parts / Container
24
24
5
Part Weight (Lbs.)
0.5
0.5
6
Container Tare Weight (Lbs.)
1.2
1.3
7
Gross Container Weigth
13.2
13.3
8
Number of Containers per one Layer
12
12
9
Number of Layers / Pallet Load
12
9
10
Total # of Containers / Pallet Load
144
108
11
Estimated Parts / Pallet Load
3456
2592
12
Estimated Gross Weight / Pallet Load
1951
1486
13
Advantages
Max Cube
Room for Parts at Top
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Disadvantages
Tight fit in Height
Less Parts / Pallet
© 2014 SSI Schäfer
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Container Options: 12 x 15 x4.0” vs. 12 x 15 x 5.0”
© 2014 SSI Schäfer
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NF121504RS Solution:
Parts are very close to the top and may rub on bottom of
container above it during transit.
Result
© 2014 SSI Schäfer
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NF121505AS Solution:
Parts have space at the top to prevent rub on bottom of
container above it during transit.
Result
© 2014 SSI Schäfer
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NF121505AS Solution / w Optional Lid:
Parts have space at the top allowing for optional lid for
added protection from debris.
Result
© 2014 SSI Schäfer
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In conclusion considering the
Method of Distribution First!!

Our Solution used:
–

Using the Primary / Secondary / Tertiary / Quaternary Principles,
considering Method of Distribution First!!

Primary = 53’ Truck

Secondary = 48 x 45 Pallet / Top Cap / Palletized Load

Tertiary = 12 x 15 x 5” Stack Only Container

Quaternary = Dunnage is the Printed Carton shipped to the Customer.
We are now working in Maximized Cube for Logistics!!!
© 2014 SSI Schäfer
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Thank you for your interest in
SSI SCHAEFER SYSTEMS INTERNATIONAL
Packaging Systems Division
packaging.ssi-schaefer.us
© 2014 SSI Schäfer
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