Customer Profile
A Tier 1 manufacturer and supplier of door and headliner components in the automotive industry.
Challenge
The customer required a reusable packaging system for storing and transporting door components without the high cost of complex, plastic or metal fabricated handling units. The dunnage also needed to be stackable to improve storage density and maximize warehouse efficiency.
Leaman Solution
• Engineered an end-load, partitioned corrugated packaging system designed for reuse.
• Developed a die-cut main tube that allows partitions to be assembled without glue, enhancing durability and ease of setup.
• Applied Design for Manufacturability (DFM) principles to ensure the final solution was cost-effective and scalable for production.
Outcomes
• Created a reusable, stackable, and protective packaging system for door components.
• The design simplified assembly and reduced overall packaging costs compared to traditional metal or plastic dunnage.
• Improved space efficiency in storage and transport.
Sustainability Impact
• The corrugated design offers a multi-cycle life span, allowing reuse before recycling at end of life.
• 100% recyclable materials can be reprocessed into new corrugated packaging.
• In 2024, more than 33 million tons of cardboard was recycled in the U.S., achieving a recycling rate of 69–74%—equivalent to about 90,000 tons per day, according to the American Forest and Paper Association.
• 100% recyclable materials can be reprocessed into new corrugated packaging.
• In 2024, more than 33 million tons of cardboard was recycled in the U.S., achieving a recycling rate of 69–74%—equivalent to about 90,000 tons per day, according to the American Forest and Paper Association.
Citations
American Forest and Paper Association
