How foam packaging protects metal pipes during transit

The client's challenge

To transport metal pipes (used in the construction of engines) between sites, the client had invested in metal stillages. Each stillage could hold up to six pipes, secured in place by fittings screwed into the base of the stillage. However, because the pipes were top heavy, they would lean and bang into each another. The client had tried to solve the problem by using pieces of corrugated board to separate the pipes, but these were not reusable, resulting in increased waste and recycling, and the need to continually reorder supplies.

The Antalis solution

Using a clear framework, the Antalis Packaging team worked on a reusable foam topper and base that fits every size of pipe, thus reducing movement and providing a buffer between the pipes. The cushioning solution also enables hand access to facilitate steady removal.

The process

• 1. Exploration: Antalis Packaging technologists visited the client's site to assess the issues and gain an understanding of the packing and transit processes.
   
• 2. Proposition: Using the information gathered, the team at the Antalis Smart Packaging Centre used their foam engineering know-how to design a foam topper that could fit on top of any size of pipe. A foam base was also proposed so that the pipes would no longer sit directly on the metal stillage. The foam was made with hand access either side so it could be removed easily.
   

• 3. Test: Rigorous testing was carried out to asses the solution's effectiveness and ease of use.
   
• 4. Implementation: Following a successful trial, the client implemented the foam cushioning solution across its sites.