THE CONTEXT
SAFEGUARDING QUALITY: THE IMPORTANCE OF EFFECTIVE PACKAGING IN CRITICAL SUPPLY CHAINS
In today's complex supply chain landscape, ensuring the integrity of materials like stainless steel conduits is critical. These conduits serve essential functions across sectors such as construction, power generation, data centers, telecommunications, and transportation. Each application requires that these durable components arrive undamaged and ready for immediate use to prevent project delays.
The supply chain encompasses both domestic and international locations, subjecting shipments to a range of handling practices that may result in product damage. In critical sectors, even minor delays caused by damaged goods can disrupt vital services and lead to unexpected expenses. This emphasizes the importance of reliable packaging solutions that safeguard products throughout their journey.
To address these challenges, companies are increasingly partnering with specialized packaging providers who understand the unique requirements of their respective markets. By developing robust packaging solutions, these collaborations not only guarantee safe product delivery but also uphold high quality standards and protect reputations within a competitive landscape. This strategic alignment enables companies to enhance operational efficiency and maintain customer trust in their offerings.
DRIVING SUSTAINABILITY: THE GLOBAL LEADER IN ELECTRICAL, SAFETY, AND INFRASTRUCTURE AND NEFAB'S COMMITMENT TO INNOVATION
The customer, renowned for its high-quality electrical conduit systems and cable management solutions, is committed to environmental stewardship as part of its Environmental, Social, and Governance (ESG) strategy. With manufacturing facilities worldwide, they aim to reduce greenhouse gas emissions significantly, targeting a 10% reduction in scope 1 and scope 2 emissions by 2025 compared to 2020 levels. Their goal of cutting carbon emissions by 2025 underscores their dedication to sustainability while delivering dependable products to their customers.
Nefab enhances this mission through its focus on developing innovative, sustainable packaging solutions. The company has expanded its global team of packaging engineers, leveraging technological advancements to optimize supply chains. By collaborating with customers, Nefab develops products that save both environmental and financial resources, perfectly aligning with their sustainability goals.
The shared commitment of the customer and Nefab to sustainability, cost efficiency, and high-quality standards makes them ideal partners. Together, we can effectively tackle industry challenges, reduce damages and costs, and enhance customer satisfaction while promoting a sustainable future. This partnership not only drives innovation but also reinforces our dedication to creating environmentally responsible solutions.
THE COLLABORATIVE JOURNEY OF NEFAB AND THE GLOBAL LEADER IN ELECTRICAL, SAFETY, AND INFRASTRUCTURE
In 2023, Nefab and the customer launched a collaborative project at the customer’s manufacturing facility in Indiana. This partnership aimed to leverage combined expertise across the Americas, with plans to expand successful solutions to Canada and explore opportunities in EMEA and APAC.
As a global leading company, Nefab is well-positioned to enhance the customer’s manufacturing footprint and facilitate the rollout of sustainable solutions in diverse markets. Together, the two companies are set to meet evolving customer needs while reinforcing a commitment to sustainability and driving growth in an increasingly competitive landscape.
KEY HIGHLIGHTS
Innovative Packaging Solution: The introduction of the ExPak system significantly improved the customer’s packaging by providing a more robust and efficient solution. This not only reduced damages during transport but also enhanced the professional presentation of their premium products. | Sustainability and Cost Efficiency: The partnership led to significant CO2 savings of 36% and cost reductions amounting to a couple of million dollars. The innovative design of the ExPak minimized waste and shipping volume, resulting in a more streamlined supply chain and reduced operational costs for the customer. | Enhanced Customer Satisfaction: With the new packaging solution, the customer was able to ensure that their products reached customers in pristine condition. This improvement in product delivery led to increased customer satisfaction and reinforced the customer’s reputation for quality in the market. |
CUSTOMER CHALLENGE: PACKAGING DILEMMAS FOR THEIR PRODUCTS
The project centered on the customer’s brand, known for its high-quality stainless steel conduit systems manufactured at their facility in Indiana, USA. The customer aimed to create a packaging solution in-house by sourcing materials such as fiberboard and inch-thick plywood end caps.
IN-HOUSE PACKAGING EFFORT
In their current packaging method, the customer combined fiberboard with plywood caps and secured the boxes with tape. However, there were opportunities for improvement. Occasionally, the fiberboard would separate from the wood, creating gaps between the conduits and end caps, which led to products being damaged and bent during transit.
CHALLENGES WITH CURRENT PACKAGING SOLUTIONS
Additionally, the wooden runners—blocks used at the bottom—were positioned in a way that could complicate the loading process. Their orientation sometimes snagged during transport, making it slightly more challenging to load the products onto trucks efficiently.
COMMITMENT TO CUSTOMER SATISFACTION
The customer was committed to showcasing its premium products in the best light possible. Customer feedback highlighted opportunities for improvement regarding product protection during transit, prompting the customer to enhance its packaging solutions. By addressing concerns related to product damage and bending, the customer took proactive steps to ensure that their high-quality offerings reached customers in optimal condition, ultimately enhancing the overall customer experience.
THE PATH FORWARD: A PREMIUM PACKAGING SOLUTION
Recognizing the importance of quality presentation, the customer actively pursued a more robust and visually appealing packaging solution. This initiative aimed to better reflect the high standards of their product line and ensure that their customers received their products in optimal condition.
THE SOLUTION
THE SOLUTION: NEFAB EXPAK
To address the customer’s packaging challenges, Nefab proposed the ExPak solution, a robust solution tailored to meet their needs. This innovative packaging directly tackled issues of product damage and enhanced branding and aesthetics, aligning with the customer’s commitment to delivering premium products.
ADVANTAGES OF EXPAK
The ExPak solution stood out for several reasons. First and foremost, its design was significantly more resilient than traditional fiberboard, greatly minimizing the risk of damage during transport. Additionally, its visually appealing aesthetic presented a polished image at their end customer's location, reinforcing the customer’s reputation for quality.
EFFICIENCY AND AUTOMATION
One of the key advantages of the ExPak system was its ease of assembly. Unlike the previous packaging solution that required nailing and stapling, ExPak could be quickly assembled with minimal tools. This streamlined the handling process and enhanced worker safety by eliminating the need for nail guns and similar equipment.
Another benefit was the efficient use of space; by utilizing ExPak, the customer no longer needed to manufacture packaging in-house. This freed up valuable space in their facility, allowing for repurposing the area without requiring additional space for packaging production.
Moreover, the ExPak solution was optimized for high-volume fulfillment. It could ship flat and stackable, significantly reducing freight costs. By minimizing air space within the packaging, the customer was able to transport more products at once, maximizing efficiency in outbound logistics. The ExPak was designed to fit at 10 feet (3.05m) long, perfectly accommodating conduits, with an option for a larger 12-foot (3.66m) solution to meet varied customer requirements.
ENHANCED LOADING AND STABILITY
To further improve usability, Nefab incorporated lengthwise runners and angled end pieces, simplifying the loading process onto trucks. Additionally, a fox brace was integrated into the design to enhance stability, allowing for quicker assembly while ensuring that products remained secure during transport.
COST SAVINGS AND ENVIRONMENTAL BENEFITS
The customer also benefited from substantial cost savings, including reductions in freight expenses and labor time for assembly. The use of GreenCalc reports provided valuable insights into their savings, allowing the customer to visualize the efficiency improvements achieved through the ExPak solution.
CONCLUSION: A TAILORED SOLUTION
In summary, the Nefab ExPak was a collapsible packaging solution designed to endure tough transport conditions while offering cost-effective protection for valuable goods. With its customizable features, including flexible sizes and thickness of plywood, the ExPak could be tailored to meet specific requirements. It allowed for easy access from all sides, logical packing and unpacking, and could be reused multiple times, making it an ideal solution for the customer as they continued to uphold their reputation for quality and excellence.
A BETTER TOMORROW
The collaboration between Nefab and the customer has resulted in a positive change; by working together, both companies have helped reduce environmental impact in supply chains.
The customer’s mission centers on developing innovative products and solutions that "power and protect the world." They strive to create value for employees, customers, suppliers, and shareholders through a steadfast commitment to sustainability and efficient operations. Emphasizing collaboration, they promote the theme of "Building Better Together," showcasing their dedication to enhancing efficiency and support across various sectors. This holistic approach underscores their goal of driving progress and delivering exceptional results for all stakeholders.
Together, Nefab is committed to leading the transformation alongside customers, with a strong foundation and bold ambitions. By providing smarter packaging and logistics solutions that reduce total costs and CO2 emissions in supply chains, we aim to add value to our customers, society, and the environment.