Introduction
An automotive manufacturer was experiencing ongoing damage to radiators during transit across two product lines.
At the same time, their packaging system had grown unnecessarily complex — using multiple SKUs to support similar products, increasing inventory, handling errors, and operational inefficiencies.
They needed a solution that would protect the product, simplify operations, and reduce cost — without sacrificing performance.
The Challenge
Damaged Radiators in Transit
Radiators were arriving with consistent damage, creating:
- Product loss
- Increased returns
- Strain on customer relationships
Excessive SKU Complexity
The existing packaging setup required:
- 4 packaging SKUs for just 2 products
- More inventory to manage
- Higher storage requirements
- Increased risk of packing errors
More SKUs = more cost, more complexity, more risk
The Solution
A Universal Corrugated Insert
We engineered a single insert design that securely holds both radiator SKUs:
- Custom fit to protect critical components
- Designed for real-world shipping conditions
- Eliminates the need for multiple insert variations
A Single Master Shipper
We paired the insert with:
- One master carton compatible across both products
- Streamlined pack-out process
- Reduced handling variability
One insert. One box. Total simplification.
The Results
50% Reduction in Packaging SKUs
- Consolidated from 4 SKUs down to 2
- Simplified inventory and procurement
Damage Eliminated in Transit
- Improved product protection
- Reduced returns and replacements
Operational Efficiency Gains
- Less warehouse space required
- Faster, more consistent packing process
- Reduced opportunity for human error
Smarter packaging. Stronger supply chain.
Schedule a Packaging Audit
If you’re dealing with damage, inefficiencies, or unnecessary packaging complexity, we can help.
Schedule a packaging audit with Leaman Container and we’ll identify opportunities to reduce cost, improve protection, and simplify your system.